Danfoss VLT Compressor Drive CDS 803 Guida utente

Operating Guide

VLT® Compressor Drive CDS 803

drives.danfoss.com

1

2

3

4

5

6

7

8

Languages

American English 3

Chinese simplied 40

French 77

German 115

Italian 154

Brazilian Portuguese 193

Russian 232

Spanish 275

Operating Guide | VLT® Compressor Drive CDS 803 Languages

1

1.1

1.2

1.3

1.4

1.5

1.6

2

2.1

2.2

2.3

2.4

3

3.1

3.1.1

3.1.2

3.1.3

3.2

3.2.1

3.2.2

3.2.3

3.2.3.1

3.2.3.2

3.2.3.3

3.2.3.4

3.2.4

3.2.4.1

3.2.4.2

3.2.4.3

3.2.4.4

3.2.4.5

3.2.5

3.2.6

3.2.6.1

3.2.6.2

Contents

Introduction 5

Purpose of this Operating Guide 5

Trademarks 5

Additional Resources 5

Manual and Software Version 5

Type Approvals and Certications 5

Disposal 5

Safety 7

Safety Symbols 7

Qualied Personnel 7

Safety Precautions 7

Motor Thermal Protection 8

Installation 9

Mechanical Installation 9

Cooling Capacity 9

Side-by-side Installation 9

Drive Dimensions 10

Electrical Installation 11

Electrical Installation in General 11

IT Grid 11

Mains and Motor Connection 11

Introduction 11

Connecting to Mains and Motor 12

Relays and Terminals on Enclosure Sizes H3–H5 14

Relays and Terminals on Enclosure Size H6 15

Fuses and Circuit Breakers 15

Branch Circuit Protection 15

Short-circuit Protection 15

Overcurrent Protection 15

UL/Non-UL Compliance 15

Recommendation of Fuses 16

EMC-correct Electrical Installation 16

Control Terminals 18

Accessing the Control Terminals 18

Setting the Control Terminals to Run the Compressor 18

Contents

VLT® Compressor Drive CDS 803

Operating Guide

American English

3.2.7

4

4.1

4.2

4.3

4.4

4.5

4.6

4.7

4.8

5

5.1

5.2

6

6.1

6.2

6.3

6.4

6.4.1

6.4.2

6.5

6.5.1

6.5.2

6.5.3

6.5.4

6.5.5

6.5.6

6.5.7

6.5.8

6.5.9

6.5.10

6.5.11

6.5.12

6.5.13

6.5.14

6.6

Electrical Wiring 19

Programming 20

Local Control Panel (LCP) 20

Start-up Quick Guide for Open-loop Applications 21

Start-up Quick Guide for Compressor Functions 23

Start-up Quick Guide for Compressor Closed-loop Applications 24

Changes Made 27

Changing Parameter Settings 27

Accessing All Parameter via the Main Menu 27

Main Menu Structure 28

Troubleshooting 29

Acoustic Noise or Vibration 29

List of Warnings and Alarms 29

Specications 32

Mains Supply 3x200–240 V AC 32

Mains Supply 3x380–480 V AC 32

EMC Emission Test Results 33

Special Conditions 34

Derating for Ambient Temperature and Switching Frequency 34

Derating for Low Air Pressure and High Altitudes 34

General Technical Data 34

Protection and Features 34

Mains Supply (L1, L2, L3) 35

Compressor Output (U, V, W) 35

Cable Lengths and Cross-sections 35

Digital Inputs 35

Analog Inputs 35

Analog Outputs 36

Digital Outputs 36

Control Card, RS485 Serial Communication 36

Control Card, 24 V DC Output 36

Relay Outputs, Enclosure Sizes H3–H5 36

Relay Outputs, Enclosure Size H6 37

Control Card, 10 V DC Output 37

Ambient Conditions 37

Options for VLT® Compressor Drive CDS 803 38

Contents

VLT® Compressor Drive CDS 803

Operating Guide

American English

•

1 Introduction

1.1 Purpose of this Operating Guide

This operating guide provides information for safe installation and commissioning of the AC drive. It is intended for use by qualied

personnel. Read and follow the instructions to use the drive safely and professionally. Pay particular attention to the safety instruc-

tions and general warnings. Always keep this operating guide available with the drive.

1.2 Trademarks

VLT

®

is a registered trademark for Danfoss A/S.

1.3 Additional Resources

Other resources are available to understand advanced drive functions and programming.

The programming guide provides greater detail on working with parameters and shows many application examples.

The design guide provides detailed information about capabilities and functionality to design motor control systems.

Supplementary publications and manuals are available from Danfoss .

See www.danfoss.com for supplementary documentation.

VLT® Motion Control Tool MCT 10 software support

Download the software from the Service and Support download page on www.danfoss.com.

During the installation process of the software, enter CD-key 34544400 to activate the CDS 803 functionality. An activation key is

not required for using the CDS 803 functionality.

The latest software does not always contain the latest updates for the drive. Contact the local sales oce for the latest drive updates

(in the form of *.upd les), or download the drive updates from the Service and Support download page on www.danfoss.com.

1.4 Manual and Software Version

This manual is regularly reviewed and updated. All suggestions for improvement are welcome.

Table 1: Manual and Software Version

Edition

Remarks

Software version

AQ321748767627xx-xx0101

New power sizes added to product range.

6.0–10 kW (8–15 hp): Version 2.0

18–30 kW (25–40 hp): Version 1.00

1.5 Type Approvals and Certications

The following list is a selection of possible type approvals and certications for VLT® Compressor Drive CDS 803 drives:

Name of certication

Certication logo

IP20

EC Declaration of Conformity

✓

UL listed

✓

UL recognized (only valid for CDS 803 - S096)

✓

RCM

✓

EAC

✓

UkrSEPRO

089

✓

VLT® Compressor Drive CDS 803 drives having S096 in the type code (400 V AC, 18.5–30 kW (25–40 hp)) are certied to UL/EN/IEC

60730-1. The drive is also designed for systems that have to be compliant with UL/IEC/EN 60335.

For more information on UL 508C thermal memory retention requirements, refer to the section Motor Thermal Protection in the

product-specic design guide.

1.6 Disposal

Do not dispose of equipment containing electrical components together with domestic waste.

Introduction

VLT® Compressor Drive CDS 803

Operating Guide

American English

Collect it separately in accordance with local and currently valid legislation.

AQ32174876762701-000101 / 130R06276 | Danfoss A/S © | 2019.12

Introduction

VLT® Compressor Drive CDS 803

Operating Guide

American English

•

-

2 Safety

2.1 Safety Symbols

The following symbols are used in this manual:

D A N G E R

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

W A R N I N G

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

C A U T I O N

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

N O T I C E

Indicates information considered important, but not hazard-related (for example, messages relating to property damage).

2.2 Qualied Personnel

To allow trouble-free and safe operation of the unit, only qualied personnel with proven skills are allowed to transport, store, as-

semble, install, program, commission, maintain, and decommission this equipment.

Persons with proven skills:

Are qualied electrical engineers, or persons who have received training from qualied electrical engineers and are suitably ex-

perienced to operate devices, systems, plant, and machinery in accordance with pertinent laws and regulations.

Are familiar with the basic regulations concerning health and safety/accident prevention.

Have read and understood the safety guidelines given in all manuals provided with the unit, especially the instructions given in

the Operating Guide.

Have good knowledge of the generic and specialist standards applicable to the specic application.

2.3 Safety Precautions

W A R N I N G

HIGH VOLTAGE

AC drives contain high voltage when connected to AC mains input, DC supply, or load sharing. Failure to perform installation,

start-up, and maintenance by qualied personnel can result in death or serious injury.

Only qualied personnel must perform installation, start-up, and maintenance.

W A R N I N G

UNINTENDED START

When the drive is connected to AC mains, DC supply, or load sharing, the motor may start at any time. Unintended start during

programming, service, or repair work can result in death, serious injury, or property damage. Start the motor with an external

switch, a eldbus command, an input reference signal from the local control panel (LCP), via remote operation using MCT 10 soft-

ware, or after a cleared fault condition.

Disconnect the drive from the mains.

Press [O/Reset] on the LCP before programming parameters.

Ensure that the drive is fully wired and assembled when it is connected to AC mains, DC supply, or load sharing.

Safety

VLT® Compressor Drive CDS 803

Operating Guide

American English

1.

-

W A R N I N G

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 indicator lights are o.

Failure to wait the specied time after power has been removed before performing service or repair work could 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 drives.

Wait for the capacitors to discharge fully. The minimum waiting time is specied in the table Discharge time and is also visible

on the nameplate on top of the drive.

Before performing any service or repair work, use an appropriate voltage measuring device to make sure that the capacitors

are fully discharged.

Table 2: Discharge Time

Voltage [V]

Power range [kW (hp)]

Minimum waiting time (minutes)

3x200

6.0–10 (8.0–15)

15

3x400

6.0–7.5 (8.0–10)

4

3x400

10–30 (15–40)

15

W A R N I N G

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.

W A R N I N G

EQUIPMENT HAZARD

Contact with rotating shafts and electrical equipment can result in death or serious injury.

Ensure that only trained and qualied personnel perform installation, start-up, and maintenance.

Ensure that electrical work conforms to national and local electrical codes.

Follow the procedures in this manual.

C A U T I O N

INTERNAL FAILURE HAZARD

An internal failure in the drive can result in serious injury when the drive is not properly closed.

Ensure that all safety covers are in place and securely fastened before applying power.

2.4 Motor Thermal Protection

This procedure is only valid for VLT® Compressor Drive CDS 803 - S096 (18.2–30 kW/VZH088–VZH170))

Procedure

Set parameter 1-90 Motor Thermal Protection to [4] ETR trip 1 to enable the motor thermal protection function.

AQ32174876762701-000101 / 130R06278 | Danfoss A/S © | 2019.12

Safety

VLT® Compressor Drive CDS 803

Operating Guide

American English

3 Installation

3.1 Mechanical Installation

3.1.1 Cooling Capacity

Table 3: H3–H4, 400 V

Cooling capacity

400 V IP20 enclosure

4 TR/VZH028

H3

5 TR/VZH035

H3

6.5 TR/VZH044

H4

Table 4: H4–H5, 200 V

Cooling capacity

200 V IP20 enclosure

4 TR/VZH028

H4

5 TR/VZH035

H4

6.5 TR/VZH044

H5

Table 5: H5–H6, 400 V

Cooling capacity

400 V IP20 enclosure

13 TR/VZH088

H5

17 TR/VZH117

H5

26 TRVZH170

H6

3.1.2 Side-by-side Installation

The drive can be mounted side by side but requires the clearance specied in Table 6 above and below for cooling.

Table 6: Clearance Required for Cooling

Power [kW (hp)]

Clearance above/below [mm (in)]

Size

IP protection rating

3x200–240 V

3x380–480 V

H3

IP20

–

6.0–7.5 (8.0–10)

100 (4)

H4

IP20

6.0–7.5 (8.0–10)

10 (15)

100 (4)

H5

IP20

10 (15)

18.5–22 (25–30)

100 (4)

H6

IP20

–

30(40)

200 (7.9)

N O T I C E

With IP21/NEMA Type1 option kit mounted, a distance of 50 mm (2 in) between the units is required.

Installation

VLT® Compressor Drive CDS 803

Operating Guide

American English

3.1.3 Drive Dimensions

e

f

a

e

f

a

d

e

A

a

b

B

C

D

e30bf984.10

Illustration 1: Dimensions

Table 7: Dimensions, Enclosure Sizes H3–H6

Enclosure

Power [kW (hp)]

Height [mm (in)]

Width [mm (in)]

Size

IP protection

rating

3x200–240 V

3x380–480 V

A

(1)

a

B

b

H3

IP20

–

6.0–7.5 (8.0–10)

255 (10.0)

329 (13.0)

240 (9.4)

100 (3.9)

74 (2.9)

H4

IP20

6.0–7.5

(8.0–10)

10 (15)

296 (11.7)

359 (14.1)

275 (10.8)

135 (5.3)

105 (4.1)

H5

IP20

10 (15)

18.5–22

(25–30)

334 (13.1)

402 (15.8)

314 (12.4)

150 (5.9)

120 (4.7)

H6

IP20

–

30 (40)

518 (20.4)

595 (23.4)/635 (25),

45 kW

495 (19.5)

239 (9.4)

200 (7.9)

1

Including decoupling plate.

Table 8: Dimensions, Enclosure Sizes H3–H6

Enclosure

Power [kW (hp)]

Depth

[mm (in)]

Mounting hole [mm (in)]

Maximum weight

Size

IP protection rat-

ing

3x200–240 V

3x380–480 V

C

d

e

f

kg (lb)

H3

IP20

–

6.0–7.5 (8.0–10)

206 (8.1)

11 (0.43)

5.5 (0.22)

8.1 (0.32)

4.5 (9.9)

H4

IP20

6.0–7.5

(8.0–10)

11 (15)

241 (9.5)

12.6 (0.50)

7 (0.28)

8.4 (0.33)

7.9 (17.4)

H5

IP20

11 (15)

18.5–22

(25–30)

255 (10)

12.6 (0.50)

7 (0.28)

8.5 (0.33)

9.5 (20.9)

H6

IP20

–

30 (40)

242 (9.5)

–

8.5 (0.33)

15 (0.6)

24.5 (54)

AQ32174876762701-000101 / 130R062710 | Danfoss A/S © | 2019.12

Installation

VLT® Compressor Drive CDS 803

Operating Guide

American English

-

3.2 Electrical Installation

3.2.1 Electrical Installation in General

All cabling must comply with national and local regulations on cable cross-sections and ambient temperature. Copper conductors

are required. 75 °C (167 °F) is recommended.

Table 9: Tightening Torques for Enclosure Sizes H3–H6, 3x200–240 V & 3x380–480 V

Power [kW (hp)]

Torque [Nm (in-lb)]

Enclo-

sure size

IP protec-

tion rating

3x200–240 V

3x380–480 V

Mains

Motor

DC connec-

tion

Control ter-

minals

Ground

Relay

H3

IP20

–

6.0–7.5 (8.0–10)

0.8 (7)

0.5 (4)

0.8 (7)

0.5 (4)

H4

IP20

6.0–7.5 (8.0–

10)

10–15 (15–20)

1.2 (11)

0.5 (4)

0.8 (7)

0.5 (4)

H5

IP20

10 (15)

18.5–22 (25–30)

1.2 (11)

0.5 (4)

0.8 (7)

0.5 (4)

H6

IP20

–

30 (40)

4.5 (40)

–

0.5 (4)

3 (27)

0.5 (4)

3.2.2 IT Grid

C A U T I O N

IT GRID

Installation on isolated mains source, that is, IT mains.

Ensure that the supply voltage does not exceed 440 V (3x380–480 V units) when connected to mains.

N O T I C E

This is only relevant for 200–240 V and 380–400 V drives in power sizes 6.0–10 kW (8.0–15 hp).

Open the RFI switch by removing the screw on the side of the drive when at IT grid.

e30bb612.10

1

Illustration 2: IP20, 200–240 V, 380–480 V, 6.0–10 kW (8.0–15 hp)

1

EMC screw

On 380–480 V, 18.5–30 kW (25–40 hp) units, the RFI lter cannot be switched o.

3.2.3 Mains and Motor Connection

3.2.3.1 Introduction

The drive is designed to operate Danfoss VZH Compressors.

Installation

VLT® Compressor Drive CDS 803

Operating Guide

American English

•

1.

2.

Use a shielded/armored motor cable to comply with EMC emission specications and connect this cable to both the decoupling

plate and the motor.

Keep the motor cable as short as possible to reduce the noise level and leakage currents.

For further details on mounting the decoupling plate, see VLT® Compressor Drive CDS 803 Decoupling Plate Installation Instruc-

tion.

Also see EMC-correct Installation in the 1.3.2.5 EMC-correct Electrical Installation

3.2.3.2 Connecting to Mains and Motor

Mount the 2 screws in the mounting plate, slide the plate into place, and tighten fully.

-DC+DC

BR- BR+ U

V

W

99

M A I N S

95

RELA

Y 1 RELA

Y 2

- L

C +

e30ba261.10

Mount the ground cables to the ground terminal before mounting other cables.

AQ32174876762701-000101 / 130R062712 | Danfoss A/S © | 2019.12

Installation

VLT® Compressor Drive CDS 803

Operating Guide

American English

3.

e30ba262.10

M

I N S

+DC

BR-

BR+

U

V

W

RELA Y 1 RELA Y 2

95

Connect the compressor to terminals U, V, and W, and then tighten the screws according to the torques described in 1.3.2.1

Electrical Installation in General.

MO T OR

MO

T

OR

U

V

W

99

e30bt302.12

Table 10: Connection of Compressor to Terminals

Drive terminals

Compressor

U

T1

V

T2

W

T3

Installation

VLT® Compressor Drive CDS 803

Operating Guide

American English

4.

5.

Connect the mains supply to terminals L1, L2, and L3, and then tighten the screws according to the torques.

e30ba263.10

95

M

A

INS

+DC

BR-

BR+

U

V

W

91

92

93

L1

L2

L3

RELA

Y 1 RELA

Y 2

Tighten support bracket on mains wires.

3.2.3.3 Relays and Terminals on Enclosure Sizes H3–H5

e30bb634.10

1

2

3

4

M

ot

or

U

V

W

-DC

+DC

M

AINS

Illustration 3: Enclosure Sizes H3–H5, IP20, 200–240 V, 6.0–10 kW (8.0–15 hp), IP20, 380–480 V, 6.0–22 kW (8.0–30 hp)

AQ32174876762701-000101 / 130R062714 | Danfoss A/S © | 2019.12

Installation

VLT® Compressor Drive CDS 803

Operating Guide

American English

1

Mains

2

Ground

3

Compressor

4

Relays

3.2.3.4 Relays and Terminals on Enclosure Size H6

1

95

99

L1 91 / L2 92 / L3 93

U 96 /

V 97 /

W 98

03 02 01

06 05 04

2

3

4

e30bb762.11

Illustration 4: Enclosure Size H6, IP20, 380–480 V, 30 kW (40 hp)

1

Mains

2

Motor

3

Ground

4

Relays

3.2.4 Fuses and Circuit Breakers

3.2.4.1 Branch Circuit Protection

To prevent re hazards, protect the branch circuits in an installation - switch gear, machines, and so on - against short circuits and

overcurrent. Follow national and local regulations.

3.2.4.2 Short-circuit Protection

Danfoss recommends using the fuses and circuit breakers listed in this chapter to protect service personnel or other equipment in

case of an internal failure in the unit or a short circuit on the DC link. The drive provides full short-circuit protection in case of a short

circuit on the motor.

3.2.4.3 Overcurrent Protection

Provide overload protection to avoid overheating of the cables in the installation. Overcurrent protection must always be carried

out according to local and national regulations. Design circuit breakers and fuses for protection in a circuit capable of supplying a

maximum of 100000 A

rms

(symmetrical), 480 V maximum.

3.2.4.4 UL/Non-UL Compliance

To ensure compliance with UL or IEC 61800-5-1, use the circuit breakers or fuses listed in this chapter. Circuit breakers must be de-

signed for protection in a circuit capable of supplying a maximum of 10000 A

rms

(symmetrical), 480 V maximum.

Installation

VLT® Compressor Drive CDS 803

Operating Guide

American English

•

3.2.4.5 Recommendation of Fuses

N O T I C E

If malfunction occurs, failure to follow the protection recommendation may result in damage to the drive.

Table 11: Fuses

Fuse

UL

Non-UL

Bussmann

Maximum fuse

Power [kW (hp)]

Type RK5

Type RK1

Type J

Type T

Type G

3x200–240 V IP20

6.0 (8.0)

FRS-R-50

KTN-R50

JKS-50

JJN-50

50

7.5 (10)

FRS-R-50

KTN-R50

JKS-50

JJN-50

50

10 (15)

FRS-R-80

KTN-R80

JKS-80

JJN-80

65

3x380–480 V IP20

6.0 (8.0)

FRS-R-25

KTS-R25

JKS-25

JJS-25

25

7.5 (10)

FRS-R-25

KTS-R25

JKS-25

JJS-25

25

10 (15)

FRS-R-50

KTS-R50

JKS-50

JJS-50

50

18.5 (25)

FRS-R-80

KTS-R80

JKS-80

JJS-80

63

22 (30)

FRS-R-80

KTS-R80

JKS-80

JJS-80

63

30 (40)

FRS-R-125

KTS-R125

JKS-R125

JJS-R125

80

3.2.5 EMC-correct Electrical Installation

General points to be observed to ensure EMC-correct electrical installation:

Use only shielded/armored motor cables and shielded/armored control cables.

Ground the shield at both ends.

Avoid installation with twisted shield ends (pigtails), because it reduces the shielding eect at high frequencies. Use the cable

clamps provided.

AQ32174876762701-000101 / 130R062716 | Danfoss A/S © | 2019.12

Installation

VLT® Compressor Drive CDS 803

Operating Guide

American English

•

Ensure the same potential between the drive and the ground potential of PLC.

Use star washers and galvanically conductive installation plates.

B

a

c

k

OK

Com.

On

Warn.

Alarm

Hand

On

Reset

Auto

On

Menu

Status Quick

Menu

Main

Menu

L1

L2

L3

PE

Minimum 16 mm

2

equalizing cable

Control cables

All cable entries in

one side of panel

Grounding rail

Cable insula-

tion stripped

Output con-

tactor

Motor cable

Motor, 3 phases and

PLC

Panel

Mains-supply

Minimum 200 mm (7.87 in)

between control

cable, mains cable

and between mains

motor cable

PLC

protective earth

Reinforced protective earth

e30bb761.12

(6 AWG)

Illustration 5: EMC-correct Electrical Installation

Installation

VLT® Compressor Drive CDS 803

Operating Guide

American English

1.

2.

1.

2.

3.

4.

3.2.6 Control Terminals

3.2.6.1 Accessing the Control Terminals

Procedure

To activate the snap, place a screwdriver behind the terminal cover.

e30bb622.11

Illustration 6: Removing the Terminal Cover

Tilt the screwdriver outwards to open the cover.

3.2.6.2 Setting the Control Terminals to Run the Compressor

e30bb625.11

12 20 55

20

27

29 42 45

55

50 53 54

GND

DIGI IN/OUT

61

68

69

N

P

COMM. GND

+24 V

DIGI IN

10 V/20 mA IN

0/4-20m A A OUT/DIG OUT

0/4-20 mA A OUT/DIG OUT

10 V OUT

BUS TER.

OFF

ON

Illustration 7: Overview of the Control Terminals

Procedure

Apply a start signal on terminal 18.

Connect terminals 12, 27, and terminal 53, 54, or 55.

Set the functions of digital inputs 18, 19, and 27 in parameter 5-00 Digital Input Mode (PNP is default value).

Set the function of digital input 29 in parameter 5-03 Digital Input 29 Mode (PNP is default value).

Installation

VLT® Compressor Drive CDS 803

Operating Guide

American English

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