Enclosure Design Handbook Rev. 1

ENCLOSURE DESIGN

HANDBOOK 1.1

Cristóbal Guerrero 2014

Enclosure Design Handbook

A) Enclosure Denomination System:

Type Array Number of

Motors

VFD Brand

Drive Option

Frame Size

Voltage NEMA Rating

Size of

Enclosure

1 2 3 4 5 6 7 8 9

1. - Type:

S = Standard Enclosure Model

C = Custom Enclosure Model

2. - Array:

SM = Single Motor

MM = Multiple Motors

3. - Number of Motors

Standard enclosures consider a maximum of 4 motors wired to a single VFD, above that number it will

become a custom enclosure model.

4. - VFD Brand

ABB = ABB

DAN = Danfoss

YAS = Yaskawa

5. - Drive Option

BD = Bare Drive Wired To Disconnect

BO = Bare Drive Without Disconnect

ID = Drive With Integral Disconnect

EM = Drive With Electromechanical Bypass by ELI

IB = Drive With Integrated Bypass.

RD = Drive With Redundant Circuit by ELI.

IR = Drives With Integrated Redundant Package.

6. – Frame

Name of VFD frame size (e.g. ABB drives are named R1 thru R6)

7. - Voltage

Incoming nominal voltage for power: 460V, 230V, 208V.

8. - NEMA Rating

National Electrical Manufactures Association rating of electrical enclosures for protection against

designated environmental conditions (e.g. NEMA 3R).

9. - Size

Nominal size of the electrical enclosure (Wide x Height X Depth).

Example:

S-MM-4-ABB-BD-R3-460V-3R-00Wx00Hx00D.

Standard enclosure with multiple motors (4), ABB Bare Drive with Disconnect R3 Frame, 460V, NEMA

3R.

Note: For multiple VFDs and common circuits in a single enclosure please refer to “B) General

considerations” under section 4 “Estimating an enclosure size based in a standard enclosure”.

B) General Considerations.

1. – Electrical Schematics.

The panel layout will always be based of the electrical schematic, in order to determine how a panel will

be assembled, the electrical schematic has to be finished first, that is to accurately know the number of

devices, required clearance for objects and routing, in addition to this our software tool (Eplan Pro Panel)

bases all its routing logic of the schematic.

2. – Compliance.

All of the panels made by energy labs must comply with the following:

UL 508A: UL Standard for Safety for Industrial Panels.

UL 1995: UL for Safety for Heating and Cooling Equipment.

NFPA 70 – NEC 2014 (National Electrical Code 2014).

3. – Device Placement.

3.1 Disconnects, circuit breakers and switches: a good place to start for the layout of an enclosure is

placing the disconnect means, standard sizes that ELI uses for disconnects switches (or breakers) are 100A,

250A, 400A, 800A, 1000A. By NEC article 110.26 (see internal standard CS-036-005 also) the requirement

for maximum height of working space is 6 ½ ft (Figure 3.1.0).

Fig. 3.1.0 Maximum height of the switch handle.

When placing a disconnect inside a tall enclosure, or with large incoming cable gauges (1/0 AWG or 150A

and larger), the disconnect must be placed in the bottom of the enclosure, to facilitate wire handling and

avoid surpassing the maximum working height (Figure 3.1.1).

Fig. 3.1.1 Large fused disconnect placed near the bottom of the enclosure.

Note: If the vestibule or enclosure requires louvers on the door for ventilation and the disconnect has

been placed near the bottom, louvers must be placed on the upper front or side walls of the enclosure to

evade interfering with the placement of the shaft and handle mechanism (Figure 3.1.2).

Fig. 3.1.2 Louvers placed in the upper front on the door of an electrical compartment.

For regular enclosures circuit breakers or disconnect switches should be mounted to the right of and/or

above the corresponding regulator module in a position which minimizes cable or bus bar length and

bends. Switch or CB handles should mount on the right most cabinet door. CB power connections should

be on top or right side.

3.2 Fuses: The recommended mounting position for fuses is vertical. Power must be applied at the top

and load connected to the bottom of the fuse. If the fuse has to be mounted horizontally, power should

be applied to the left side of the fuse.

3.3 Contactors: Contactors should be grouped together and preferably mounted in a horizontal manner.

Number contactors left to right and top to bottom.

3.4 Motor Circuit Protectors and Overload Relays: MCPs should be grouped together, the recommended

position is horizontal, but they can be mounted in a vertical manner as well. Overload relays are usually

mounted directly beneath contactors, if not they must be place close as to avoid excessive cable length,

since both MCPs and OR are directly upstream of motors, they are typically mounted in the lowest part

or border of an enclosure.

3.5 Relays: Relays should be grouped together and mounted with sockets vertical. Common connections

at bottom or right side of coil. Number relays left to right and top to bottom.

3.6 Terminals: The preferred location for terminals is mounted in a vertical line on the left or right edge

of panel. Separate control signal voltages (below 50 VAC or DC) from other voltages. Leave a minimum

1.25” between terminal and wire way or nearest component. Leave a minimum of 3” between terminals

and cabinet walls. Consider using a bracket to elevate terminals above panel to avoid mixing voltages

(Class 1 from Class 2) and evade skirting connections thru raceways (Figure 3.4.0). Where possible, place

terminals between 36” and 72” from floor level and in no case less than 12” off the floor.

Figure 3.4.0 Rail placed above brackets.

3.7 Variable-speed drive (VFDs): Drives are placed commonly on the corners of an electrical panel, the

installation manual (provided by the drive manufacturer), specifies the required clearance of each frame,

this clearance is required for heat dissipation, servicing and troubleshooting purposes, even if the drive

does not require side or front clearance, for handling and service, there must be a provision of at least

1.5” to the sides, and 4” to the front (if the VFD is surface mounted on the machine, it must have a

clearance of at least 46”).

3.8 Heavy Items: Transformers and other heavy objects should be mounted to panel with a bolt through

if weight is greater than 50 lbs. extremely heavy items (above 100 lbs.) may require additional bracing of

the sub panel. When mounting extremely heavy items (above 100 lbs.) use tapped holes with screws

run in from the back.

3.9 Cooling:

4. - Estimating an enclosure size based in a standard enclosure.

Appendix B contains standard enclosures models, based in the most common circuit configurations Energy

Labs offers.

When in need for a quick dimension of the area needed for an enclosure, pick a model that mostly

resembles the configuration needed, and elaborate on what components are going to be added to that

enclosure, below are some guidelines for common devices.

Control Circuits:

Relays and terminals are placed on rail in a vertical manner, adding an extra redundant or bypass circuit

to an enclosure, will increase its height by approximately 10”.

Power Circuits:

Drives: VFDs are preferably placed side by side, they can be stacked, but in between them a deflector

must be added, evade this configuration to avoid overheating, when adding drives consider the width of

the frame of the drive plus the side clearance (1.5-2.5” for small drives, 2.5-3” for larger drives 40 HP and

above), and add the result to the width of the enclosure.

Fuses, contactors and motor circuit protectors, can add up to 5Wx5H per device, usually these

components will be place side by side, when adding an extra redundant or bypass circuit these

components space requirements must be added to the width and height of the enclosure.

Miscellaneous Circuits:

Lighting loads and service circuits, usually need extra components like transformers, terminals, fuses and

circuit breakers, these usually increase the height to the enclosure, to determine how much space is going

to be needed please consult the electrical department, as they do not have a standard value for the space

required.

Appendix A. Electrical Templates.

Electrical Templates are schematics that represent the most common arrays and options energy labs

offers to its clients, the electrical department created them to standardize labeling and representation of

components and devices, in addition electrical templates are created as macro projects (smart blocks)

which contain databases (place holder objects) that make the drafting process easier.

The current templates in use can be located on Eplan under project names:

Electrical Templates 2014.elk

Electrical Templates II - 2014.elk

DESCRIPTION PROJECT NAME FILE HYPERLINK

MOTOR STARTER Electrical Templates 2014.elk MSET2014

MOTOR TO J-BOX Electrical Templates 2014.elk MTJBET2014

MOTOR TO DANFOSS VFD Electrical Templates 2014.elk MTDVET2014

MOTOR TO YASKAWA VFD Electrical Templates 2014.elk MTYVET2014

MOTOR TO ABB VFD Electrical Templates 2014.elk MTAVET2014

MOTOR TO DANFOSS VFD W/ BYPASS Electrical Templates 2014.elk MTDVEMBET2014

MOTOR TO YASKAWA VFD W/ BYPASS Electrical Templates 2014.elk MTYVEMBET2014

MOTOR TO ABB VFD W/ BYPASS Electrical Templates 2014.elk MTAVEMBET2014

REDUNDANT DANFOSS SYSTEM Electrical Templates 2014.elk RDVSET2014

REDUNDANT YASKAWA SYSTEM Electrical Templates 2014.elk RYVSET2014

REDUNDANT ABB SYSTEM Electrical Templates 2014.elk RAVSET2014

MULTIPLE MOTORS TO DANFOSS VFD Electrical Templates II - 2014.elk MMDVET2014

MULTIPLE MOTORS TO YASKAWA VFD Electrical Templates II - 2014.elk MMYVET2014

MULTIPLE MOTORS TO ABB VFD Electrical Templates II - 2014.elk MMAVET2014

MULTIPLE MOTORS TO DANFOSS VFD WITH BYPASS Electrical Templates II - 2014.elk MMDVEMET2014

MULTIPLE MOTORS TO YASKAWA VFD WITH BYPASS Electrical Templates II - 2014.elk MMYVEMET2014

MULTIPLE MOTORS TO ABB VFD WITH BYPASS Electrical Templates II - 2014.elk MMAVEMET2014

REDUNDANT DANFOSS SYSTEM MULTIPLE MOTORS Electrical Templates II - 2014.elk RDSMMET2014

REDUNDANT YASKAWA SYSTEM MULTIPLE MOTORS Electrical Templates II - 2014.elk RYSMMET2014

REDUNDANT ABB SYSTEM MULTIPLE MOTORS Electrical Templates II - 2014.elk RASMMET2014

Appendix B. Standard Enclosures.

All enclosures were created using as a basis the largest load each VFD frame can handle, so in some cases

the enclosure can have smaller sizes, the last digits of the mounting panel 3D model indicate the required

dimensions. Enclosures models are contained inside the following Eplan projects:

ABB Standard Enclosures Part I.elk (ABB Drives to Single Motor Arrangements)

ABB Standard Enclosures Part II.elk (ABB Drives to Multiple 4 Motor Arrangements)

Danfoss Standard Enclosures Part I.elk (Danfoss Drives to Single Motor Arrangements)

Danfoss Standard Enclosures Part II.elk (Danfoss Drives to Multiple 4 Motor Arrangements)

Yaskawa Standard Enclosures Part I.elk (Yaskawa Drives to Single Motor Arrangements)

Yaskawa Standard Enclosures Part II.elk (Yaskawa Drives to Multiple 4 Motor Arrangements)

Note: Appendix D contains a quick reference guide for the frame sizes and ratings of each manufacturer.

For enclosures highlighted in yellow, an electrical compartment for large drives, devices and cable gauges

is preferred, consult with electrical engineering before applying them, it is recommended that anything

above 42Wx70H is turned in to a vestibule, doors for an enclosure or compartment should not exceed

42W and 72H.

ENCLOSURE DESIGNATION

DESCRIPTION MOUNTING PANEL 3D MODEL

SSM1ABBBOR1 ABB R1 Bare Drive With Out Disconnect S-SM-1-ABB-BO-R1-XXXV-XX-12Wx32Hx12D






SSM1ABBBDR1 ABB R1 Bare Drive With Disconnect S-SM-1-ABB-BD-R1-XXXV-XX-22Wx32Hx12D






SSM1ABBEMR1 ABB R1 Drive With EM Bypass By ELI S-SM-1-ABB-EM-R1-XXXV-XX-22Wx50Hx12D






SSM1ABBRDR1 ABB R1 Drive With Redundant Circuit S-SM-1-ABB-RD-R1-XXXV-XX-28Wx54Hx12D






SSM1DANBOA2 Danfoss A2 Bare Drive With Out Disconnect S-SM-1-DAN-BO-A2-XXXV-XX-12Wx24Hx12D

SSM1DANBOA3 Danfoss A3 Bare Drive With Out Disconnect S-SM-1-DAN-BO-A3-XXXV-XX-14Wx24Hx12D

SSM1DANBOB1 Danfoss B1 Bare Drive With Out Disconnect S-SM-1-DAN-BO-B1-XXXV-XX-16Wx36Hx14D

SSM1DANBOB2 Danfoss B2 Bare Drive With Out Disconnect S-SM-1-DAN-BO-B2-XXXV-XX-16Wx44Hx14D

SSM1DANBOC1 Danfoss C1 Bare Drive With Out Disconnect S-SM-1-DAN-BO-C1-XXXV-XX-20Wx44Hx16D

SSM1DANBOC2 Danfoss C2 Bare Drive With Out Disconnect S-SM-1-DAN-BO-C2-XXXV-XX-22Wx50Hx18D

SSM1DANBDA2 Danfoss A2 Bare Drive With Disconnect S-SM-1-DAN-BD-A2-XXXV-XX-20Wx26Hx12D

SSM1DANBDA3 Danfoss A3 Bare Drive With Disconnect S-SM-1-DAN-BD-A3-XXXV-XX-22Wx26Hx12D

SSM1DANBDB1 Danfoss B1 Bare Drive With Disconnect S-SM-1-DAN-BD-B1-XXXV-XX-28Wx36Hx14D

SSM1DANBDB2 Danfoss B2 Bare Drive With Disconnect S-SM-1-DAN-BD-B2-XXXV-XX-28Wx44Hx14D

SSM1DANBDC1 Danfoss C1 Bare Drive With Disconnect S-SM-1-DAN-BD-C1-XXXV-XX-34Wx44Hx16D

SSM1DANBDC2 Danfoss C2 Bare Drive With Disconnect S-SM-1-DAN-BD-C2-XXXV-XX-44Wx50Hx18D

SSM1DANEMA2 Danfoss A2 Drive With EM Bypass By ELI S-SM-1-DAN-EM-A2-XXXV-XX-20Wx44Hx12D

SSM1DANEMA3 Danfoss A3 Drive With EM Bypass By ELI S-SM-1-DAN-EM-A3-XXXV-XX-22Wx44Hx12D

SSM1DANEMB1 Danfoss B1 Drive With EM Bypass By ELI S-SM-1-DAN-EM-B1-XXXV-XX-32Wx50Hx14D

SSM1DANEMB2 Danfoss B2 Drive With EM Bypass By ELI S-SM-1-DAN-EM-B2-XXXV-XX-32Wx58Hx14D

SSM1DANEMC1 Danfoss C1 Drive With EM Bypass By ELI S-SM-1-DAN-EM-C1-XXXV-XX-42Wx62Hx16D

SSM1DANEMC2 Danfoss C2 Drive With EM Bypass By ELI S-SM-1-DAN-EM-C2-XXXV-XX-48Wx78Hx18D

SSM1DANRDA2 Danfoss A2 Drive With Redundant Circuit S-SM-1-DAN-RD-A2-XXXV-XX-26Wx46Hx12D

SSM1DANRDA3 Danfoss A3 Drive With Redundant Circuit S-SM-1-DAN-RD-A3-XXXV-XX-30Wx46Hx12D

SSM1DANRDB1 Danfoss B1 Drive With Redundant Circuit S-SM-1-DAN-RD-B1-XXXV-XX-42Wx60Hx14D

SSM1DANRDB2 Danfoss B2 Drive With Redundant Circuit S-SM-1-DAN-RD-B2-XXXV-XX-42Wx66Hx14D

SSM1DANRDC1 Danfoss C1 Drive With Redundant Circuit S-SM-1-DAN-RD-C1-XXXV-XX-52Wx68Hx16D

SSM1DANRDC2 Danfoss C2 Drive With Redundant Circuit S-SM-1-DAN-RD-C2-XXXV-XX-56Wx86Hx18D

SSM1YASBOF1 Yaskawa F1 Bare Drive With Out Disconnect S-SM-1-YAS-BO-F1-XXXV-XX-12Wx26Hx12D






SSM1YASBDF1 Yaskawa F1 Bare Drive With Disconnect S-SM-1-YAS-BD-F1-XXXV-XX-22Wx26Hx12D






SSM1YASEMF1 Yaskawa F1 Drive With EM Bypass By ELI S-SM-1-YAS-EM-F1-XXXV-XX-22Wx44Hx12D






SSM1YASRDF1 Yaskawa F1 Drive With Redundant Circuit S-SM-1-YAS-RD-F1-XXXV-XX-28Wx48Hx12D






SMM4ABBBOR1 ABB R1 Bare Drive With Out Disconnect & Multiple Motors

S-MM-4-ABB-BO-R1-XXXV-XX-14Wx42Hx12D











SMM4ABBBDR1 ABB R1 Bare Drive With Disconnect & Multiple Motors

S-MM-4-ABB-BD-R1-XXXV-XX-24Wx36Hx12D











SMM4ABBEMR1 ABB R1 Drive With EM Bypass By ELI Multiple Motors

S-MM-4-ABB-EM-R1-XXXV-XX-24Wx52Hx12D











SMM4ABBRDR1 ABB R1 Drive With Redundant Circuit & Multiple Motors

S-MM-4-ABB-RD-R1-XXXV-XX-28Wx54Hx12D











SMM4DANBOA2 Danfoss A2 Bare Drive With Out Disconnect & Multiple Motors

S-MM-4-DAN-BO-A2-XXXV-XX-16Wx36Hx12D

SMM4DANBOA3 Danfoss A3 Bare Drive With Out Disconnect & Multiple Motors

S-MM-4-DAN-BO-A3-XXXV-XX-16Wx36Hx12D

SMM4DANBOB1 Danfoss B1 Bare Drive With Out Disconnect & Multiple Motors

S-MM-4-DAN-BO-B1-XXXV-XX-16Wx48Hx14D

SMM4DANBOB2 Danfoss B2 Bare Drive With Out Disconnect & Multiple Motors

S-MM-4-DAN-BO-B2-XXXV-XX-18Wx58Hx14D

SMM4DANBOC1 Danfoss C1 Bare Drive With Out Disconnect & Multiple Motors

S-MM-4-DAN-BO-C1-XXXV-XX-34Wx48Hx16D

SMM4DANBOC2 Danfoss C2 Bare Drive With Out Disconnect & Multiple Motors

S-MM-4-DAN-BO-C2-XXXV-XX-38Wx52Hx18D

SMM4DANBDA2 Danfoss A2 Bare Drive With Disconnect & Multiple Motors

S-MM-4-DAN-BD-A2-XXXV-XX-22Wx34Hx12D

SMM4DANBDA3 Danfoss A3 Bare Drive With Disconnect & Multiple Motors

S-MM-4-DAN-BD-A3-XXXV-XX-24Wx34Hx12D

SMM4DANBDB1 Danfoss B1 Bare Drive With Disconnect & Multiple Motors

S-MM-4-DAN-BD-B1-XXXV-XX-30Wx40Hx14D

SMM4DANBDB2 Danfoss B2 Bare Drive With Disconnect & Multiple Motors

S-MM-4-DAN-BD-B2-XXXV-XX-30Wx44Hx14D

SMM4DANBDC1 Danfoss C1 Bare Drive With Disconnect & Multiple Motors

S-MM-4-DAN-BD-C1-XXXV-XX-34Wx72Hx16D

SMM4DANBDC2 Danfoss C2 Bare Drive With Disconnect & Multiple Motors

S-MM-4-DAN-BD-C2-XXXV-XX-38Wx84Hx18D

SMM4DANEMA2 Danfoss A2 Drive With EM Bypass By ELI Multiple Motors

S-MM-4-DAN-EM-A2-XXXV-XX-22Wx52Hx12D

SMM4DANEMA3 Danfoss A3 Drive With EM Bypass By ELI Multiple Motors

S-MM-4-DAN-EM-A3-XXXV-XX-24Wx52Hx12D

SMM4DANEMB1 Danfoss B1 Drive With EM Bypass By ELI Multiple Motors

S-MM-4-DAN-EM-B1-XXXV-XX-32Wx52Hx14D

SMM4DANEMB2 Danfoss B2 Drive With EM Bypass By ELI Multiple Motors

S-MM-4-DAN-EM-B2-XXXV-XX-32Wx68Hx14D

SMM4DANEMC1 Danfoss C1 Drive With EM Bypass By ELI Multiple Motors

S-MM-4-DAN-EM-C1-XXXV-XX-46Wx72Hx16D

SMM4DANEMC2 Danfoss C2 Drive With EM Bypass By ELI Multiple Motors

S-MM-4-DAN-EM-C2-XXXV-XX-54Wx88Hx18D

SMM4DANRDA2 Danfoss A2 Drive With Redundant Circuit & Multiple Motors

S-MM-4-DAN-RD-A2-XXXV-XX-26Wx46Hx12D

SMM4DANRDA3 Danfoss A3 Drive With Redundant Circuit & Multiple Motors

S-MM-4-DAN-RD-A3-XXXV-XX-30Wx46Hx12D

SMM4DANRDB1 Danfoss B1 Drive With Redundant Circuit & Multiple Motors

S-MM-4-DAN-RD-B1-XXXV-XX-42Wx60Hx14D

SMM4DANRDB2 Danfoss B2 Drive With Redundant Circuit & Multiple Motors

S-MM-4-DAN-RD-B2-XXXV-XX-42Wx66Hx14D

SMM4DANRDC1 Danfoss C1 Drive With Redundant Circuit & Multiple Motors

S-MM-4-DAN-RD-C1-XXXV-XX-46Wx86Hx16D

SMM4DANRDC2 Danfoss C2 Drive With Redundant Circuit & Multiple Motors

S-MM-4-DAN-RD-C2-XXXV-XX-56Wx104Hx18D

SMM4YASBOF1 Yaskawa F1 Bare Drive With Out Disconnect & Multiple Motors

S-MM-4-YAS-BO-F1-XXXV-XX-14Wx36Hx12D











SMM4YASBDF1 Yaskawa F1 Bare Drive With Disconnect& Multiple Motors

S-MM-4-YAS-BD-F1-XXXV-XX-22Wx36Hx12D

SMM4YASBDF2 Yaskawa F2 Bare Drive With Disconnect & Multiple Motors










SMM4YASEMF1 Yaskawa F1 Drive With EM Bypass By ELI Multiple Motors

S-MM-4-YAS-EM-F1-XXXV-XX-24Wx52Hx12D











SMM4YASRDF1 Yaskawa F1 Drive With Redundant Circuit & Multiple Motors

S-MM-4-YAS-RD-F1-XXXV-XX-28Wx48Hx12D







SMM4YASRDF5 Yaskawa F5 Drive With Redundant Circuit& Multiple Motors




Special Devices Enclosures.

ENCLOSURE DESIGNATION

DESCRIPTION MOUNTING PANEL 3D MODEL

Ebtron Transmitter with Cover 14Wx24Hx6D

Ebtron Transmitter without Cover 14Wx16Hx6D

Appendix C. Parts Management (3D Macros) for Eplan Pro Panel.

For implementing the 3D design of enclosures, parts had to be uploaded to Eplan Pro Panel, these parts

are called “Macros” and they are created in macro projects, the following table shows a brief list (with

the name) of the projects, and what kind of devices were created in those projects.

PROJECT NAME DESCRIPTION

ABB Drive Macros ABB Drives Frames R1 thru R6.

Circuit Breakers And Switches Macros Molded Case Circuit Breakers, Automated Molded Case Switches and Other Disconnect Means.

Contactor Macros Contactors and Accessories.

Danfoss VFDs Macros Danfoss Drives Frames A2 thru C2.

Fuses Macros Fuses, Fuse Covers & Fuse Blocks.

Miniature Circuit Breakers Miniature Circuit Breakers & Protectors.

Motor Circuit Protectors Macros MCPs and Accessories.

Overload Relay Macros Overload Relays And Accessories.

PDB Macros Power Distribution Blocks.

Pilot Devices Macros Pilot Lights, Switches, Buttons, Selectors.

Relay Macros Relays and Accessories.

Terminal Macros Terminals and Accessories.

Transformer Macros Control and Power Transformers.

Yaskawa VFDS Macros Yaskawa Drives Frame 1 thru 6.

Appendix D. Drive Frame Sizes By Manufacturer

Appendix E. Enclosure Formulas.

Legend

c = Clearance

w = Width

h = Height

d = Depth

VFD = Variable Frequency Drive

K = Contactor

R = Relay (Coil and Soquet)

F = Fuse (Complete Assembly, Fuse Block, Fuse Covers, Fuses)

Enclosure Design Handbook Rev. 1

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