Danfoss iC7 Series User manual

1 Overview
1.1 Description
The in-bottom/out-top cooling kit fits FA09 and FA10 frequency converters in Rittal cabinets of 2000 mm (79 in) in height, and 600
mm (24 in) or 800 mm (31 in) wide. When the kit is installed, air flows into the bottom duct and out through the top duct of the
frequency converter. See Illustration 1.
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3
4
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2
e30be921.10
Illustration 1: Direction of Airflow with Kit Installed
1
Back channel airflow (exhaust)
2
Frequency converter
3
Back channel airflow (intake)
4
Top duct assembly
5
Bottom duct assembly
1.2 Kit Numbers
Use these instructions with the following kits.
Table 1: In-bottom/Out-top Cooling Kits
Number
Kit description
176F4038
In-bottom/out-top cooling kit for FA09 frequency converter
176F4039
In-bottom/out-top cooing kit for FA10 frequency converter
AN371942791357en-000101 / 136R0254 | 1Danfoss A/S © 2022.03
Installation Guide
In-bottom/Out-top Cooling Kit for FA09-FA10
iC7 Series Frequency Converters

1.3 Items Supplied
The kit contains the following parts:
Table 2: Contents of In-bottom/Out-top Cooling Kit
Item
Quantity
Telescopic top duct assembly
1
Telescopic bottom duct assembly
1
Cutout gasket
1
Ribbed EPDM rubber seal
1
Strip gasket
1
Seal plate gasket
2
Seal plate
2
Duct support plate
1
Duct support plate gasket
1
M10x30 screws
4
M5x16 countersunk screw
7
M5x18 screw
4-5
M5x10 screw
10-11
M5 hex nut
6
AN371942791357en-000101 / 136R02542 | Danfoss A/S © 2022.03
Overview
In-bottom/Out-top Cooling Kit for FA09-FA10
Installation Guide

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2 Installation
2.1 Safety Information
NOTICE
QUALIFIED PERSONNEL
Only qualified personnel are allowed to install the parts described in these installation instructions.
Disassembly and reassembly of the frequency converter must be done in accordance with the corresponding service guide.
Use the standard fastener torque values from the service guide, unless the torque value is specified in these instructions.
WARNING
ELECTRICAL SHOCK HAZARD
The frequency converter contains dangerous voltages when connected to mains voltage. Improper installation, and installing or
servicing with power connected, can cause death, serious injury, or equipment failure.
Only use qualified electricians for the installation.
Disconnect the frequency converter from all power sources before installation or service.
Treat the frequency converter as live whenever the mains voltage is connected.
Follow the guidelines in these instructions and local electrical safety codes.
WARNING
DISCHARGE TIME (20 MINUTES)
The frequency converter contains DC-link capacitors, which can remain charged even when the frequency converter is not pow-
ered. High voltage can be present even when the warning indicator lights are off.
Failure to wait 20 minutes after power has been removed before performing service or repair work can result in death or serious
injury.
Stop the motor.
Disconnect AC mains, permanent magnet type motors, and remote DC-link supplies, including battery back-ups, UPS, and
DC-link connections to other frequency converters.
Wait 20 minutes for the capacitors to discharge fully before performing any service or repair work.
Measure the voltage level to verify full discharge.
NOTICE
ELECTROSTATIC DISCHARGE
Electrostatic discharge can damage components.
Ensure discharge before touching internal frequency converter components, for example by touching a grounded, conduc-
tive surface or by wearing a grounded armband.
AN371942791357en-000101 / 136R0254 | 3Danfoss A/S © 2022.03
Installation
In-bottom/Out-top Cooling Kit for FA09-FA10
Installation Guide

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2.2 Installation Overview
NOTICE
APPLYING GASKETS
This kit contains self-adhesive gaskets to ensure a proper seal between metal parts.
Before affixing a gasket, check that the part matches the gasket and that no holes are covered.
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9
5
6
e30bj161.10
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4
1
3
Illustration 2: Overview of In-bottom/Out-top Cooling Kit
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Installation
In-bottom/Out-top Cooling Kit for FA09-FA10
Installation Guide

1.
2.
1
Frequency converters
2
Duct support plate
3
Rittal cabinet
4
Base plate
5
Top plate
6
Top duct assembly
7
Mounting plate
8
Mounting holes
9
Bottom duct assembly
10
Back plate
2.3 Creating a Vent Opening in the Top Plate
To create a vent opening in the cabinet top plate, use the following steps. Use the dimensions in Illustration 3 for the FA09 top
plate, and Illustration 4 for the FA10 top plate.
Procedure
Cut out the vent opening in the Rittal cabinet top plate using the dimensions in the template.
The opening must match the top duct opening.
Drill 6 screw holes (4 mm) around the vent opening using the dimensions in the template.
The holes must match the holes in the upper flange of the top duct.
191 (7.5)
223 (8.8)
80 (3.1)
6x Ø 4 (0.2)
14 (0.6)
95 (3.7)
95 (3.7)
3 (0.1)
e30bj065.10
Illustration 3: FA09 Rittal Cabinet Top Plate Template
AN371942791357en-000101 / 136R0254 | 5Danfoss A/S © 2022.03
Installation
In-bottom/Out-top Cooling Kit for FA09-FA10
Installation Guide

1.
2.
e30bj068.10
56 (2.2)
180 (7.1)
17 (0.7)
138 (5.5)
128 (5.0)
8 (0.3)
291 (8.6)
323 (12.7)
16 (0.6)
6x Ø 6 (0.2)
Illustration 4: FA10 Rittal Cabinet Top Plate Template
2.4 Creating a Vent Opening in the Base Plate
To create a vent opening in the base plate for the bottom duct, use the following steps. Use the dimensions in Illustration 5 for FA09
frequency converters, and Illustration 6 for FA10 frequency converters.
Procedure
Cut out the vent opening in the cabinet base plate using the dimensions in the template.
Drill 6 screw holes (4 mm) around the vent opening using the dimensions in the template.
The holes must match the holes in the lower flange of the bottom duct.
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Installation
In-bottom/Out-top Cooling Kit for FA09-FA10
Installation Guide

e30bg400.10
275 (10.8)
0.0
208 (8.2)
201 (7.9)
64 (2.5)
51 (2.0)
0.0
222 (8.7) 227 (8.9) 245 (9.6) 415 (16.3) 432 (17.0) 438 (17.2) 660 (26.0)
4x Ø 4 (0.2)
Illustration 5: FA09 Base Plate Template
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Installation
In-bottom/Out-top Cooling Kit for FA09-FA10
Installation Guide

1.
46 (1.8)
e30bg441.10
0.0
275 (10.8)
208 (8.2)
203 (8.0)
64 (2.5)
45 (1.8)
0.0
172 (6.8) 178 (7.0) 195 (7.7) 330 (13.0) 465 (18.3) 488 (19.2) 482 (19.0)
5x Ø 4 (0.2)
Illustration 6: FA10 Base Plate Template
2.5 Preparing the Mounting Plate
To create holes in the mounting plate, use the following steps. Use the dimensions in Illustration 7 for FA09 frequency converters,
and in Illustration 8 for FA10 frequency converters.
Procedure
Drill 4 holes in the mounting plate using the dimensions in the template.
The mounting holes must match the holes in the frequency converter.
AN371942791357en-000101 / 136R02548 | Danfoss A/S © 2022.03
Installation
In-bottom/Out-top Cooling Kit for FA09-FA10
Installation Guide

2. Insert 4 M10 pem self-clinching nuts (not supplied) in the mounting holes.
844 (33.2)
2x Ø 8 (0.3)
Drive Mounting Holes
e30bj064.10
200 (7.9)
180 (7.1)
2x Ø 8 (0.3)
Drive Mounting Holes
Illustration 7: FA09 Mounting Plate Template
AN371942791357en-000101 / 136R0254 | 9Danfoss A/S © 2022.03
Installation
In-bottom/Out-top Cooling Kit for FA09-FA10
Installation Guide

1.
a.
b.
2.
e30bj067.10
2x Ø 8 (0.3)
Drive Mounting Holes
280 (11.0)
1051 (41.4)
271 (10.7)
2x Ø 8 (0.3)
Drive Mounting Holes
Illustration 8: FA10 Mounting Plate Template
2.6 Assembling the Ducts
The top and bottom ducts are telescopic ducts that collapse to simplify installation. To assemble the ducts before installation, use
the following steps. Refer to Illustration 9.
Procedure
Cut the strip of ribbed EPDM rubber seal into 4 pieces. Use the following measurements:
For FA09 frequency converters, cut 2 strips of 581 mm (22.9 in) for the top duct, and 2 strips of 682 mm (26.9 in) for
the bottom duct.
For FA10 frequency converters, cut 2 strips of 849 mm (33.4 in) for the top duct, and 2 strips of 877 mm (34.5 in) for
the bottom duct.
Peel the paper off the self-adhesive seals. Place 1 strip on the outside bottom edge of the inner sleeve of each duct, and 1
strip on the upper inside edge of the outer sleeve of each duct.
AN371942791357en-000101 / 136R025410 | Danfoss A/S © 2022.03
Installation
In-bottom/Out-top Cooling Kit for FA09-FA10
Installation Guide

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With the rubber seal in place, carefully slide the inner sleeve of each duct into the outer sleeve.
e30bj178.10
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2
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Illustration 9: Assembly of Telescopic Ducts
1
Inner sleeve of duct
2
Ribbed EPDM rubber seal
3
Outer sleeve of duct
2.7 Mounting the Frequency Converter
To install the mounting plate and frequency converter in the Rittal cabinet, use the following steps. Refer to Illustration 10.
Procedure
Attach the mounting plate to the cabinet rails, making sure that the pem nuts face the back of the cabinet.
Remove the backing paper from the self adhesive on the cutout gasket.
Affix the gasket over the duct opening in the mounting plate.
Remove the backing paper from the self adhesive on the strip gasket.
Affix the gasket over the lower 2 pem nuts in the mounting plate.
Remove the backing paper from the 2 seal plate gaskets, and affix the gaskets to the seal plates, 1 per plate.
Fasten 2 M10x30 screws through the seal plates, 1 per plate, and into the pem nuts at the lower end of the mounting plate.
Make sure that the screws are secure. The base of the frequency converter rests on the screws.
Slightly lean the top of the frequency converter forward and set the cutouts in the base onto the 2 screws.
Slowly push the top of the frequency converter back against the mounting plate until the top 2 pem nuts line up with the
holes in the frequency converter.
AN371942791357en-000101 / 136R0254 | 11Danfoss A/S © 2022.03
Installation
In-bottom/Out-top Cooling Kit for FA09-FA10
Installation Guide

10. Secure the top of the frequency converter using 2 M10x30 screws.
Torque all M10x30 screws to 19 Nm (170 in-lb).
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e30bj122.10
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3
4
5
6
8
9
10
Illustration 10: Installation of the Frequency Converter in the Cabinet
1
Mounting holes
2
M10x30 screw
3
Frequency converter
4
Seal plate gasket
5
Seal plate
6
M10x30 screw
7
Pem nuts
8
Cutout gasket
9
Mounting plate
10
Strip gasket
AN371942791357en-000101 / 136R025412 | Danfoss A/S © 2022.03
Installation
In-bottom/Out-top Cooling Kit for FA09-FA10
Installation Guide

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2.8 Installing the Duct Support Plate
The duct support plate attaches the bottom duct to the lower end of the frequency converter. To install the duct support plate, use
the following steps. Refer to Illustration 11.
Procedure
Remove the paper backing from the duct support plate gasket.
Adhere the gasket to the upper surface of the duct support plate.
Position the duct support plate at the lower end of the frequency converter.
Secure the duct support plate to the frequency converter using 7 M5x16 countersunk screws (T25).
Torque fasteners to 2.3 Nm (20 in-lb).
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3
4
e30bj141.10
1
Illustration 11: Installation of the Duct Support Plate
1
Frequency converter
2
Duct support plate gasket
3
Duct support plate
4
M5x16 countersunk screw
2.9 Installing the Bottom Duct
To attach the bottom duct to the base plate of the cabinet, use the following steps. Refer to Illustration 12.
Procedure
Install the base plate in the Rittal cabinet using the existing fasteners.
Collapse the bottom duct and position it over the vent cutout in the base plate.
Place the holes in the lower flange of the duct over the holes surrounding the opening in the plate.
Fasten 4 M5x10 screws (T25) through the holes in the lower flange of the duct, securing it to the base plate.
AN371942791357en-000101 / 136R0254 | 13Danfoss A/S © 2022.03
Installation
In-bottom/Out-top Cooling Kit for FA09-FA10
Installation Guide

5. Extend the duct upward and fasten with 6 M5 hex nuts, securing it to the duct support plate.
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2
3
6
5
4
e30bj142.10
Illustration 12: Installation of the Bottom Duct
1
M5 hex nut
2
Bottom telescopic duct
3
M5x16 screw
4
Base plate
5
Duct support plate
6
Lower flange of duct
2.10 Installing the Top Duct
Attach the top telescopic duct between the top of the frequency converter and the cabinet using the following steps. Refer
to .Illustration 13 (The top plate of the cabinet is removed from the illustration for visibility of parts).
Procedure
AN371942791357en-000101 / 136R025414 | Danfoss A/S © 2022.03
Installation
In-bottom/Out-top Cooling Kit for FA09-FA10
Installation Guide

1.
2.
3.
4.
Collapse the top duct and position it over the vent in the top of the frequency converter.
Secure the duct to the top of the frequency converter with 4 M5x18 screws.
Extend the telescopic duct upward until the upper flange of the duct is positioned against the underside of the cabinet top
plate.
Secure the duct to the top plate with 6 M5x10 screws (T25) through the upper flange of the duct.
Torque fasteners to 2.3 Nm (20 in-lb).
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2
3
4
e30bj143.10
Illustration 13: Installation of the Top Duct
1
M5x10 screw
2
Telescopic top duct
3
M5x18 screw
4
Upper flange of duct
AN371942791357en-000101 / 136R0254 | 15Danfoss A/S © 2022.03
Installation
In-bottom/Out-top Cooling Kit for FA09-FA10
Installation Guide

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*136R0254*
*M00315* AN371942791357en-000101 / 136R025416 | Danfoss A/S © 2022.03
Installation
In-bottom/Out-top Cooling Kit for FA09-FA10
Installation Guide