Danfoss VLT FC 103 User manual

ENGINEERING TOMORROW
Operating Guide
VLT® Refrigeration Drive FC 103
355–800 kW, Enclosure Sizes E1h–E4h
vlt-drives.danfoss.com

Contents
1 Introduction 4
1.1 Purpose of the Manual 4
1.2 Additional Resources 4
1.3 Manual and Software Version 4
1.4 Approvals and Certications 4
1.5 Disposal 4
2 Safety 5
2.1 Safety Symbols 5
2.2 Qualied Personnel 5
2.3 Safety Precautions 5
3 Product Overview 7
3.1 Intended Use 7
3.2 Power Ratings, Weights, and Dimensions 7
3.3 Interior View of Enclosures E1h and E2h 8
3.4 Interior View of Enclosures E3h and E4h 9
3.5 Control Shelf 10
3.6 Local Control Panel (LCP) 11
4 Mechanical Installation 13
4.1 Items Supplied 13
4.2 Tools Needed 13
4.3 Storage 13
4.4 Operating Environment 13
4.5 Installation and Cooling Requirements 15
4.6 Lifting the Unit 15
4.7 E1h/E2h Mechanical Installation 16
4.8 E3h/E4h Mechanical Installation 18
5 Electrical Installation 22
5.1 Safety Instructions 22
5.2 EMC-compliant Installation 22
5.3 Wiring Schematic 25
5.4 Connecting the Motor 26
5.5 Connecting the AC Mains 28
5.6 Connecting to Ground 30
5.7 Terminal Dimensions 32
5.8 Control Wiring 42
Contents Operating Guide
MG16P222 Danfoss A/S © 04/2018 All rights reserved. 1

5.9 Pre-start Check List 47
6 Commissioning 49
6.1 Safety Instructions 49
6.2 Applying Power 49
6.3 LCP Menu 50
6.4 Programming the Drive 51
6.5 Testing Before System Start-up 54
6.6 System Start-up 55
6.7 Parameter Settings 55
7 Wiring Conguration Examples 57
7.1 Wiring for Open-loop Speed Control 57
7.2 Wiring for Start/Stop 58
7.3 Wiring for External Alarm Reset 60
7.4 Wiring for a Motor Thermistor 60
7.5 Wiring for Regeneration 61
8 Maintenance, Diagnostics, and Troubleshooting 62
8.1 Maintenance and Service 62
8.2 Heat Sink Access Panel 62
8.3 Status Messages 63
8.4 Warning and Alarm Types 66
8.5 List of Warnings and Alarms 66
8.6 Troubleshooting 76
9 Specications 79
9.1 Electrical Data 79
9.2 Mains Supply 83
9.3 Motor Output and Motor Data 83
9.4 Ambient Conditions 83
9.5 Cable Specications 84
9.6 Control Input/Output and Control Data 84
9.7 Fuses 87
9.8 Enclosure Dimensions 88
9.9 Enclosure Airow 104
9.10 Fastener Torque Ratings 105
10 Appendix 106
10.1 Abbreviations and Conventions 106
Contents VLT® Refrigeration Drive FC 103
2 Danfoss A/S © 04/2018 All rights reserved. MG16P222

10.2 International/North American Default Parameter Settings 107
10.3 Parameter Menu Structure 107
Index 112
Contents Operating Guide
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1 Introduction
1.1 Purpose of the Manual
This operating guide provides information for safe instal-
lation and commissioning of the VLT®drives in an
enclosure size E (E1h, E2h, E3h, and E4h).
The operating guide is intended for use by qualied
personnel. To use the unit safely and professionally, read
and follow this operating guide. Pay particular attention to
the safety instructions and general warnings. Always keep
the operating guide with the drive.
VLT®is a registered trademark.
1.2 Additional Resources
Other resources are available to understand advanced E1h–
E4h drive functions and programming.
•The VLT
®
Refrigeration Drive FC 103 Programming
Guide provides greater detail on working with
parameters and refrigeration application
examples.
•The VLT
®
HVAC Drive FC 102, 90–1200 kW Design
Guide provides detailed capabilities and
functionality to design motor control systems for
refrigeration applications.
•The Safe Torque O Operating Guide provides
detailed specications, requirements, and instal-
lation instructions for the Safe Torque O
function.
Supplementary publications and manuals are available
from Danfoss. See www.danfoss.com/en/search/?lter=type
%3Adocumentation for listings.
1.3 Manual and Software Version
This manual is regularly reviewed and updated. All
suggestions for improvement are welcome. Table 1.1 shows
the version of the manual and the corresponding software
version.
Manual version Remarks Software
version
MG16P2xx Added output contactor
warning and other corrections.
1.51
Table 1.1 Manual and Software Version
1.4 Approvals and Certications
Table 1.2 Approvals and Certications
More approvals and certications are available. Contact the
local Danfoss oce or partner. Drives of voltage T7 (525–
690 V) are UL certied for only 525–690 V.
The drive complies with UL 61800-5-1 thermal memory
retention requirements. For more information, refer to the
section Motor Thermal Protection in the product-specic
design guide.
NOTICE
IMPOSED LIMITATIONS ON THE OUTPUT
FREQUENCY
From software version 1.10, the output frequency of the
drive is limited to 590 Hz due to export control
regulations.
1.4.1 Compliance with ADN
For compliance with the European Agreement concerning
International Carriage of Dangerous Goods by Inland
Waterways (ADN), refer to ADN-compliant Installation in the
design guide.
1.5 Disposal
Do not dispose of equipment containing
electrical components together with
domestic waste.
Collect it separately in accordance with
local and currently valid legislation.
Introduction VLT® Refrigeration Drive FC 103
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11

2 Safety
2.1 Safety Symbols
The following symbols are used in this guide:
WARNING
Indicates a potentially hazardous situation that could
result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation that could
result in minor or moderate injury. It can also be used to
alert against unsafe practices.
NOTICE
Indicates important information, including situations that
can result in damage to equipment or property.
2.2 Qualied Personnel
Correct and reliable transport, storage, installation,
operation, and maintenance are required for the trouble-
free and safe operation of the drive. Only qualied
personnel are allowed to install or operate this equipment.
Qualied personnel are dened as trained sta, who are
authorized to install, commission, and maintain equipment,
systems, and circuits in accordance with pertinent laws and
regulations. Also, the personnel must be familiar with the
instructions and safety measures described in this manual.
2.3 Safety Precautions
WARNING
HIGH VOLTAGE
Drives contain high voltage when connected to AC mains
input, DC supply, load sharing, or permanent motors.
Failure to use qualied personnel to install, start up, and
maintain the drive can result in death or serious injury.
•Only qualied personnel must install, start up,
and maintain the drive.
WARNING
UNINTENDED START
When the drive is connected to the AC mains, DC supply,
or load sharing, the motor can start at any time.
Unintended start during programming, service, or repair
work can result in death, serious injury, or property
damage. The motor can start with an external switch, a
eldbus command, an input reference signal from the
LCP or LOP, via remote operation using MCT 10 Set-up
Software, or after a cleared fault condition.
To prevent unintended motor start:
•Press [O/Reset] on the LCP before
programming parameters.
•Disconnect the drive from the mains.
•Completely wire and assemble the drive, motor,
and any driven equipment before connecting
the drive to the AC mains, DC supply, or load
sharing.
WARNING
DISCHARGE TIME
The drive contains DC-link capacitors, which can remain
charged even when the drive is not powered. High
voltage can be present even when the warning LED
indicator lights are o. Failure to wait 40 minutes after
power has been removed before performing service or
repair work can result in death or serious injury.
1. Stop the motor.
2. Disconnect AC mains and remote DC-link
supplies, including battery back-ups, UPS, and
DC-link connections to other drives.
3. Disconnect or lock motor.
4. Wait 40 minutes for the capacitors to discharge
fully.
5. Before performing any service or repair work,
use an appropriate voltage measuring device to
make sure that the capacitors are fully
discharged.
Safety Operating Guide
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22

WARNING
LEAKAGE CURRENT HAZARD
Leakage currents exceed 3.5 mA. Failure to ground the
drive properly can result in death or serious injury.
•Ensure the correct grounding of the equipment
by a certied electrical installer.
WARNING
EQUIPMENT HAZARD
Contact with rotating shafts and electrical equipment
can result in death or serious injury.
•Ensure that only trained and qualied personnel
install, start up, and maintain the drive.
•Ensure that electrical work conforms to national
and local electrical codes.
•Follow the procedures in this guide.
CAUTION
HOT SURFACES
The drive contains metal components that are still hot
even after the drive has been powered o. Failure to
observe the high temperature symbol (yellow triangle)
on the drive can result in serious burns.
•Be aware that internal components, such as
busbars, may be extremely hot even after the
drive has been powered o.
•Exterior areas marked by the high temperature
symbol (yellow triangle) are hot while the drive
is in use and immediately after being powered
o.
WARNING
INTERNAL FAILURE HAZARD
Under certain circumstances, an internal failure can
cause a component to explode. Failure to keep the
enclosure closed and properly secured can cause death
or serious injury.
•Do not operate the drive with the door open or
panels o.
•Ensure that the enclosure is properly closed and
secured during operation.
NOTICE
MAINS SHIELD SAFETY OPTION
A mains shield option is available for enclosures with a
protection rating of IP21/IP54 (Type 1/Type 12). The
mains shield is a cover installed inside the enclosure to
protect against the accidental touch of the power
terminals, according to BGV A2, VBG 4.
Safety VLT® Refrigeration Drive FC 103
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3 Product Overview
3.1 Intended Use
The drive is an electronic motor controller that converts AC mains input into a variable AC waveform output. The frequency
and voltage of the output are regulated to control the motor speed or torque. The drive is designed to:
•Regulate motor speed in response to system feedback or to remote commands from external controllers.
•Monitor system and motor status.
•Provide motor overload protection.
The drive is designed for industrial and commercial environments in accordance with local laws and standards. Depending
on conguration, the drive can be used in standalone applications or form part of a larger system or installation.
NOTICE
In a residential environment, this product can cause radio interference, in which case supplementary mitigation
measures can be required.
Foreseeable misuse
Do not use the drive in applications which are non-compliant with specied operating conditions and environments. Ensure
compliance with the conditions specied in chapter 9 Specications.
3.2 Power Ratings, Weights, and Dimensions
Table 3.1 provides dimensions for standard congurations. For dimensions on optional congurations, see chapter 9 Speci-
cations.
Enclosure size E1h E2h E3h E4h
Rated power at 380–480 V [kW (hp)] 355–450
(500–600)
500–560
(650–750)
355–450
(500–600)
500–560
(650–750)
Rated power at 525–690 V [kW (hp)] 450–630
(450–650)
710–800
(750–950)
450–630
(450–650)
710–800
(750–950)
Enclosure protection rating IP21/Type 1
IP54/Type 12
IP21/Type 1
IP54/Type 12
IP20/
Chassis
IP20/
Chassis
Unit dimensions
Height [mm (in)] 2043 (80.4) 2043 (80.4) 1578 (62.1) 1578 (62.1)
Width [mm (in)] 602 (23.7) 698 (27.5) 506 (19.9) 604 (23.89)
Depth [mm (in)] 513 (20.2) 513 (20.2) 482 (19.0) 482 (19.0)
Weight [kg (lb)] 295 (650) 318 (700) 272 (600) 295 (650)
Shipping dimensions
Height [mm (in)] 2191 (86.3) 2191 (86.3) 1759 (69.3) 1759 (69.3)
Width [mm (in)] 768 (30.2) 768 (30.2) 746 (29.4) 746 (29.4)
Depth [mm (in)] 870 (34.3) 870 (34.3) 794 (31.3) 794 (31.3)
Weight [kg (lb)] – – – –
Table 3.1 Enclosure Power Ratings and Dimensions
Product Overview Operating Guide
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33

3.3 Interior View of Enclosures E1h and E2h
130BF206.11
FASTENERTORQUE:
M10 19Nm (14FT-LB)
M12 35Nm (26FT-LB)
- REGEN 83
FASTENERTORQUE:
M10 19Nm (14FT-LB)
M12 35Nm (26FT-LB)
+ REGEN 82
2
6
4
511
12
9
1
7
10
8
3
1 Control shelf (see Illustration 3.3) 7 Fan power card
2 Local control panel (LCP) cradle 8 Space heater (optional)
3 RFI lter (optional) 9 Mains disconnect (optional)
4 Mains fuses (required for UL compliance, but otherwise
optional)
10 Brake/regeneration terminals (optional)
5 Mains terminals 11 Motor terminals
6 RFI shield termination 12 Ground terminals
Illustration 3.1 Interior View of Enclosure E1h (Enclosure E2h is Similar)
Product Overview VLT® Refrigeration Drive FC 103
8 Danfoss A/S © 04/2018 All rights reserved. MG16P222
33

3.4 Interior View of Enclosures E3h and E4h
FASTENERTORQUE:
M10 19Nm (14FT-LB)
M12 35Nm (26FT-LB)
+ DC 89
FASTENERTORQUE:
M10 19Nm (14FT-LB)
M12 35Nm (26FT-LB)
- BRAKE 83
FASTENERTORQUE:
M10 19Nm (14FT-LB)
M12 35Nm (26FT-LB)
+ BRAKE 82
FASTENERTORQUE:
M10 19Nm (14FT-LB)
M12 35Nm (26FT-LB)
- DC 88
130BF211.11
1
6
2
5
9
12
13
11
7
8
310
4
1 Load share/regeneration terminals (optional) 8 RFI shield termination (optional, but is standard when RFI
lter is ordered)
2 Control shelf (see Illustration 3.3) 9 Fans (used to cool the front section of enclosure)
3 Local control panel (LCP) cradle 10 Fan power card
4 RFI lter (optional) 11 Space heater (optional)
5 Mains fuses (optional) 12 Brake terminals (optional)
6 Mains terminals 13 Motor terminals
7 Ground terminals – –
Illustration 3.2 Interior View of Enclosure E3h (Enclosure E4h is Similar)
Product Overview Operating Guide
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33

3.5 Control Shelf
130BF148.11
Remove Jumper to activate Safe Stop
12 13 18 19 27 29 32 33 20 37
39 42 50 53 54 55
61 68 69
1
3
4
12
9
8
RELAY 1 RELAY 2
0102
03
040506
2
6
10
7
5
11
13
1 LCP cradle (LCP not shown) 8 Control shelf
2 Bus terminal switch
(see chapter 5.8.6 Conguring RS485 Serial Communication)
9 USB port
3 Serial communication terminals (see Table 5.1) 10 Analog input switches A53/A54
(see chapter 5.8.11 Selecting Voltage/Current Input Signal)
4 Digital input/output terminals (see Table 5.2) 11 Analog input/output terminals (see Table 5.3)
5 Cable/EMC clamps 12 Brake resistor terminals, 104–106
(on power card underneath control shelf)
6 Relay 1 and relay 2 (see Illustration 5.19) 13 Power card (underneath the control shelf)
7 Control card (underneath LCP and control terminals) – –
Illustration 3.3 View of Control Shelf
Product Overview VLT® Refrigeration Drive FC 103
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33

3.6 Local Control Panel (LCP)
The local control panel (LCP) is the combined display and keypad on the front of the drive.
The LCP is used to:
•Control the drive and motor.
•Access drive parameters and program the drive.
•Display operational data, drive status, and warnings.
A numeric local control panel (NLCP) is available as an option. The NLCP operates in a manner similar to the LCP, but there
are dierences. For details on how to use the NLCP, see the product-specic programming guide.
130BF153.11
Auto
On Reset
Hand
On Off
Status Quick
Menu
Main
Menu
Alarm
Log
Back
Cancel
Info
OK
Status 1(1)
0.00 kW
0.0 Hz
On
Alarm
Warn.
0.00 A
0.0 %
2605 kWh
A1.1
A1.2
A1.3
A2
A3
B1
B2
B4
B3
C1
C2
C3
C4
C5
D1
D2
D3
E1
E2
E3
E4
Off Remote Stop
Illustration 3.4 Graphical Local Control Panel (LCP)
A. Display area
Each display readout has a parameter associated with it. See Table 3.2. The information shown on the LCP can be
customized for specic applications. Refer to chapter 6.3.1.2 Q1 My Personal Menu.
Callout Parameter Default setting
A1.1 Parameter 0-20 Display Line 1.1 Small Reference [%]
A1.2 Parameter 0-21 Display Line 1.2 Small Motor current [A]
A1.3 Parameter 0-22 Display Line 1.3 Small Power [Kw]
A2 Parameter 0-23 Display Line 2 Large Frequency [Hz]
A3 Parameter 0-24 Display Line 3 Large kWh counter
Table 3.2 LCP Display Area
Product Overview Operating Guide
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33

B. Menu keys
Menu keys are used to access the menu for setting up
parameters, toggling through status display modes during
normal operation, and viewing fault log data.
Callout Key Function
B1 Status Shows operational information.
B2 Quick Menu Allows access to parameters for initial
set-up instructions. Also provides
detailed application steps. Refer
to chapter 6.3.1.1 Quick Menu Mode.
B3 Main Menu Allows access to all parameters. Refer to
chapter 6.3.1.8 Main Menu Mode.
B4 Alarm Log Shows a list of current warnings and the
last 10 alarms.
Table 3.3 LCP Menu Keys
C. Navigation keys
Navigation keys are used for programming functions and
moving the display cursor. The navigation keys also
provide speed control in local (hand) operation. The
display brightness can be adjusted by pressing [Status] and
[▲]/[▼] keys.
Callout Key Function
C1 Back Reverts to the previous step or list in the
menu structure.
C2 Cancel Cancels the last change or command as
long as the display mode has not changed.
C3 Info Shows a denition of the function being
shown.
C4 OK Accesses parameter groups or enables an
option.
C5 ▲▼◄►Moves between items in the menu.
Table 3.4 LCP Navigation Keys
D. Indicator lights
Indicator lights are used to identify the drive status and to
provide a visual notication of warning or fault conditions.
Callout Indicator Indicator
light
Function
D1 On Green Activates when the drive receives
power from the mains voltage or
a 24 V DC external supply.
D2 Warn. Yellow Activates when warning
conditions are active. Text
appears in the display area
identifying the problem.
D3 Alarm Red Activates during a fault
condition. Text appears in the
display area identifying the
problem.
Table 3.5 LCP Indicator Lights
E. Operation keys and reset
The operation keys are found toward the bottom of the
local control panel.
Callout Key Function
E1 Hand On Starts the drive in local control. An
external stop signal by control input or
serial communication overrides the local
Hand On.
E2 O Stops the motor but does not remove
power to the drive.
E3 Auto On Puts the system in remote operational
mode so it can respond to an external
start command by control terminals or
serial communication.
E4 Reset Resets the drive manually after a fault has
been cleared.
Table 3.6 LCP Operation Keys and Reset
Product Overview VLT® Refrigeration Drive FC 103
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33

4 Mechanical Installation
4.1 Items Supplied
Items supplied can vary according to product congu-
ration.
•Make sure the items supplied and the information
on the nameplate correspond to the order conr-
mation.
•Visually check the packaging and the drive for
damage caused by inappropriate handling during
shipment. File any claim for damage with the
carrier. Retain damaged parts for clarication.
OUT: 3x0-Vin 0-590Hz 880/780 A
IN: 3x380-480V 50/60Hz 848/752 A
500 kW / 650 HP
VLT
T/C: FC-103N500T4E20H2XGC7XXSXXXXAXBXCXXXXDX
P/N: 135N6991 S/N:
RRefrigeration Drive
www.danfoss.com
130BF733.11
ASSEMBLED IN USA
Max Tamb. 55
C/131 F at Full Output Current Derating
Tamb. 40
C/104 F at Full Output Current
SCCR 100 kA at UL Voltage range 380-480 V
Listed 36U0 E70524 IND. CONT. EQ.
UL Voltage range 380-480 V
CAUTION - ATTENTION:
Stored charge, wait 40 min.
Charge residuelle, attendez 40 min.
See manual for special condition / prefuses
Voir manuel de conditions speciales / fusibles
WARNING - AVERTISSEMENT:
`
`
123456H123
1
2
3
4
5
6
Danfoss A/S
6430 Nordborg
Denmark
CHASSIS/IP20
1 Type code
2 Code number
3 Power rating
4Input voltage, frequency, and current (at low/high
voltages)
5Output voltage, frequency, and current (at low/high
voltages)
6 Discharge time
Illustration 4.1 Product Nameplate for E4h Enclosure (Example)
NOTICE
Removing the nameplate from the drive can result in the
loss of warranty.
4.2 Tools Needed
Receiving/unloading
•I-beam and hooks rated to lift the weight of the
drive. Refer to chapter 3.2 Power Ratings, Weights,
and Dimensions.
•Crane or other lifting aid to place the unit into
position.
Installation
•Drill with 10 mm or 12 mm drill bits.
•Tape measurer.
•Various sizes of Phillips and at bladed
screwdrivers.
•Wrench with relevant metric sockets (7–17 mm).
•Wrench extensions.
•Torx drives (T25 and T50).
•Sheet metal punch for conduits or cable glands.
•I-beam and hooks to lift the weight of the drive.
Refer to chapter 3.2 Power Ratings, Weights, and
Dimensions.
•Crane or other lifting aid to place the drive onto
pedestal and into position.
4.3 Storage
Store the drive in a dry location. Keep the equipment
sealed in its packaging until installation. Refer to
chapter 9.4 Ambient Conditions for recommended ambient
temperature.
Periodic forming (capacitor charging) is not necessary
during storage unless storage exceeds 12 months.
4.4 Operating Environment
In environments with airborne liquids, particles, or
corrosive gases, ensure that the IP/Type rating of the
equipment matches the installation environment. For
specications regarding ambient conditions, see
chapter 9.4 Ambient Conditions.
Mechanical Installation Operating Guide
MG16P222 Danfoss A/S © 04/2018 All rights reserved. 13
44

NOTICE
CONDENSATION
Moisture can condense on the electronic components
and cause short circuits. Avoid installation in areas
subject to frost. Install an optional space heater when
the drive is colder than the ambient air. Operating in
standby mode reduces the risk of condensation as long
as the power dissipation keeps the circuitry free of
moisture.
NOTICE
EXTREME AMBIENT CONDITIONS
Hot or cold temperatures compromise unit performance
and longevity.
•Do not operate in environments where the
ambient temperature exceeds 55 °C (131 °F).
•The drive can operate at temperatures down to
-10 °C (14 °F). However, proper operation at
rated load is only guaranteed at 0 °C (32 °F) or
higher.
•If temperature exceeds ambient temperature
limits, extra air conditioning of the cabinet or
installation site is required.
4.4.1 Gases
Aggressive gases, such as hydrogen sulde, chlorine, or
ammonia can damage the electrical and mechanical
components. The unit uses conformal-coated circuit boards
to reduce the eects of aggressive gases. For conformal-
coating class specications and ratings, see
chapter 9.4 Ambient Conditions.
4.4.2 Dust
When installing the drive in dusty environments, pay
attention to the following:
Periodic maintenance
When dust accumulates on electronic components, it acts
as a layer of insulation. This layer reduces the cooling
capacity of the components, and the components become
warmer. The hotter environment decreases the life of the
electronic components.
Keep the heat sink and fans free from dust buildup. For
more service and maintenance information, refer to
chapter 8 Maintenance, Diagnostics, and Troubleshooting.
Cooling fans
Fans provide airow to cool the drive. When fans are
exposed to dusty environments, the dust can damage the
fan bearings and cause premature fan failure. Also, dust
can accumulate on fan blades causing an imbalance which
prevents the fans from properly cooling the unit.
4.4.3 Potentially Explosive Atmospheres
WARNING
EXPLOSIVE ATMOSPHERE
Do not install the drive in a potentially explosive
atmosphere. Install the unit in a cabinet outside of this
area. Failure to follow this guideline increases risk of
death or serious injury.
Systems operated in potentially explosive atmospheres
must fulll special conditions. EU Directive 94/9/EC
(ATEX 95) classies the operation of electronic devices in
potentially explosive atmospheres.
•Class d species that if a spark occurs, it is
contained in a protected area.
•Class e prohibits any occurrence of a spark.
Motors with class d protection
Does not require approval. Special wiring and containment
are required.
Motors with class e protection
When combined with an ATEX approved PTC monitoring
device like the VLT®PTC Thermistor Card MCB 112, instal-
lation does not need an individual approval from an
approbated organization.
Motors with class d/e protection
The motor itself has an e ignition protection class, while
the motor cabling and connection environment is in
compliance with the d classication. To attenuate the high
peak voltage, use a sine-wave lter at the drive output.
When using a drive in a potentially explosive
atmosphere, use the following:
•Motors with ignition protection class d or e.
•PTC temperature sensor to monitor the motor
temperature.
•Short motor cables.
•Sine-wave output lters when shielded motor
cables are not used.
Mechanical Installation VLT® Refrigeration Drive FC 103
14 Danfoss A/S © 04/2018 All rights reserved. MG16P222
44

NOTICE
MOTOR THERMISTOR SENSOR MONITORING
Drives with the VLT®PTC Thermistor Card MCB 112
option are PTB-certied for potentially explosive
atmospheres.
4.5 Installation and Cooling Requirements
NOTICE
Improper mounting can result in overheating and
reduced performance.
Installation requirements
•Locate the unit as near to the motor as possible.
See chapter 9.5 Cable Specications for the
maximum motor cable length.
•Ensure unit stability by mounting the unit to a
solid surface.
•Enclosures E3h and E4h can be mounted:
-Vertically on the back plate of the panel
(typical installation).
-Vertically upside down on the back
plate of the panel.1)
-Horizontally on its back, mounted on
the back plate of the panel.1)
-Horizontally on its side, mounted on
oor of the panel.1)
•Ensure that the strength of the mounting location
supports the unit weight.
•Ensure that there is enough space around the
unit for proper cooling. Refer to
chapter 9.9 Enclosure Airow.
•Ensure enough access to open the door.
•Ensure cable entry from the bottom.
1) For non-typical installation, contact the factory.
Cooling requirements
•Ensure that top and bottom clearance for air
cooling is provided. Clearance requirement:
225 mm (9 in).
•Provide sucient airow ow rate. See Table 4.1.
•Consider derating for temperatures starting
between 45 °C (113 °F) and 50 °C (122 °F) and
elevation 1000 m (3300 ft) above sea level. See
the design guide for detailed information.
The drive utilizes a back-channel cooling concept that
removes heat sink cooling air. The heat sink cooling air
carries approximately 90% of the heat out of the back
channel of the drive. Redirect the back-channel air from
the panel or room by using:
•Duct cooling
Back-channel cooling kits are available to direct
the heat sink cooling air out of the panel when
IP20/Chassis drives are installed in Rittal
enclosures. These kits reduce the heat in the
panel and smaller door fans can be specied.
•Back-wall cooling
Installing top and base covers to the unit allows
the back-channel cooling air to be ventilated out
of the room.
NOTICE
For E3h and E4h enclosures (IP20/Chassis), at least 1
door fan is required on the enclosure to remove the heat
not contained in the back-channel of the drive. It also
removes any additional losses generated by other
components inside the drive. To select the appropriate
fan size, calculate the total required airow.
Secure the necessary airow over the heat sink.
Frame Door fan/top fan
[m3/hr (cfm)]
Heat sink fan
[m3/hr (cfm)]
E1h51h 510 (300) 994 (585)
E2h 552 (325) 1053–1206 (620–710)
E3h 595 (350) 994 (585)
E4h 629 (370) 1053–1206 (620–710)
Table 4.1 Airow Rate
4.6 Lifting the Unit
Always lift the drive using the dedicated lifting eyes. To
avoid bending the lifting holes, use a bar.
Mechanical Installation Operating Guide
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WARNING
RISK OF INJURY OR DEATH
Follow local safety regulations for lifting heavy weights.
Failure to follow recommendations and local safety
regulations can result in death or serious injury.
•Ensure that the lifting equipment is in proper
working condition.
•See chapter 3.2 Power Ratings, Weights, and
Dimensions for the weight of the dierent
enclosure sizes.
•Maximum diameter for bar: 20 mm (0.8 in).
•The angle from the top of the drive to the
lifting cable: 60°or greater.
130BF685.10
Illustration 4.2 Recommended Lifting Method
4.7 E1h/E2h Mechanical Installation
The E1h and E2h enclosure size is intended only for oor
installation, and is shipped with a pedestal and a gland
plate. The pedestal and gland plate must be installed for
proper installation.
The pedestal is 200 mm (7.9 in) and has an opening in the
front to allow airow necessary to cool the power
components of the drive.
The gland plate is necessary to provide cooling air to the
control components of the drive via the door fan, and to
maintain the IP21/Type 1 or IP54/Type 12 protection rating.
4.7.1 Securing the Pedestal to the Floor
The pedestal must be secured to the oor using 6 bolts
before installing the enclosure.
1. Determine proper placement of the unit,
concerning operating conditions and cable
access.
2. Access the mounting holes by removing the front
panel of the pedestal.
3. Set the pedestal on the oor and secure using 6
bolts through the mounting holes. Refer to the
circled areas in Illustration 4.3.
130BF208.10
Illustration 4.3 Pedestal to Floor Mounting Points
Mechanical Installation VLT® Refrigeration Drive FC 103
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4.7.2 Attaching the E1h/E2h to the Pedestal
1. Lift the drive and position it on the pedestal.
There are 2 bolts in the rear of the pedestal that
slide into the 2 slotted holes in the rear of the
enclosure. Position the drive by adjusting the
bolts up or down. Loosely secure with 2 M10 nuts
and locking brackets. See Illustration 4.4.
2. Verify that there is 225 mm (9 in) top clearance
for air exhaust.
3. Verify that the air intake at the bottom front of
the unit is not obstructed.
4. Around the top of the pedestal, secure the
enclosure using 6 M10x30 fasteners. Refer to
Illustration 4.5. Loosely tighten each bolt until all
bolts are installed.
5. Fasten each bolt securely and torque to 19 Nm
(169 in-lb).
6. Torque the 2 M10 nuts at the rear of the
enclosure to 19 Nm (169 in-lb).
130BF225.10
1
2
5
4
6
3
1 Enclosure 4 Slotted hole in enclosure
2 Pedestal 5 Bolt at rear of pedestal
3 M10 nut 6 Locking bracket
Illustration 4.4 Pedestal to Enclosure Back Mounting Points
130BF207.10
1
2
3
1 Enclosure 3 M10x30 fasteners
(rear corner bolts not
shown)
2 Pedestal – –
Illustration 4.5 Pedestal to Enclosure Mounting Points
4.7.3 Creating Cable Openings
The gland plate is a sheet of metal with studs along the
outer edge. The gland plate provides cable entry and cable
termination points, and must be installed to maintain the
IP21/IP54 (Type 1/Type 12) protection rating. The plate is
placed between the drive enclosure and the pedestal.
Depending on stud orientation, the plate can be installed
from inside the enclosure or the pedestal. For gland plate
dimensions, see chapter 9.8.1 E1h Exterior Dimensions.
Refer to Illustration 4.6 for the following steps.
1. Create cable entry holes in the gland plate using
a sheet metal punch.
2. Insert the gland plate using 1 of the following
methods:
2a To insert the gland plate through the
pedestal, slide the gland plate through
the slot (4) in the front of the pedestal.
2b To insert the gland plate through the
enclosure, angle the gland plate until it
can be slid under the slotted brackets.
3. Align the studs on the gland plate to the holes in
the pedestal and secure with 10 M5 nuts (2).
4. Torque each nut to 2.3 Nm (20 in-lb).
Mechanical Installation Operating Guide
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130BF209.10
1
3
4
2
1 Cable entry hole 4 Slot in pedestal base
2 M5 nut 5 Front cover/grill
3 Gland plate – –
Illustration 4.6 Installing the Gland Plate
4.8 E3h/E4h Mechanical Installation
The E3h and E4h enclosure sizes are intended to be
mounted on a wall or on a mounting panel within an
enclosure. A plastic gland plate is installed on the
enclosure. It is designed to prevent unintentional access to
the terminals in an IP20/protected chasis unit.
NOTICE
REGENERATION/LOAD SHARE OPTION
Due to the exposed terminals at the top of the
enclosure, units with the regeneration/load share option
have an IP00 protection rating.
4.8.1 Attaching the E3h/E4h to a Mounting
Plate or Wall
1. Drill the mounting holes according to the
enclosure size. Refer to chapter 9.8 Enclosure
Dimensions.
2. Secure the top of the drive enclosure to the
mounting plate or wall.
3. Secure the base of the drive enclosure to the
mounting plate or wall.
Mechanical Installation VLT® Refrigeration Drive FC 103
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