Danfoss CD302 Installation guide
Instructions
Frequency converter CD302
Inverter reciprocating compressors VTZ
Safety instructions and General Warning
Disposal
Drive:
Equipment containing electrical components may not be disposed together
with domestic waste.
It must be separate collected with Electrical and
Electronic Waste according to local and currently
valid legislation.
Compressors:
Danfoss recommends not to thriw away a used
compressor but to a dispose of the compressor
and its oil at a specialised recycling company site
Caution
The CD 302 Compressor Drive™ DC link capacitors remain charged after power has been disconnected. To avoid an electrical shock hazard,
disconnect the CD 302 from the mains before
carrying out maintenance. Wait at least as follows
before doing service on the frequency converter:
CD 302: ≤ 7.5 kW 4 minutes
CD 302: 11 . 22 kW 15 minutes
Be aware that there may be high voltage on the
DC link even when the LEDs are turned off.
CD302 Operating Instructions Software version:
1.0x
These Operating Instructions can be used for all
CD302 Compressor Drives™ with software version
1.0x.
The software version number can be seen from
parameter 15-43.
High Voltage Warning
The voltage of the CD 302 is dangerous
whenever the converter is connected to mains.
Incorrect fitting of the motor or frequency
converter may cause damage to the equipment,
serious injury or death. Consequently, it is essential to comply with the instructions in this manual
as well as local and national rules and safety regulations.
Safety Instructions
• Make sure the CD 302 is properly connected to
earth.
• Do not remove mains plugs or motor plugs
while the CD 302 is connected to mains.
• Protect users against supply voltage.
• Protect the motor against overloading according to national and local regulations.
• Motor overload protection is included in the
default settings
• The earth leakage current exceeds 3.5 mA.
• The [OFF] key is not a safety switchIt does not
disconnect the CD 302 from mains.
General warning
Warning:
Touching the electrical parts may be fatal - even
after the equipment has been disconnected from
mains.
Also make sure that other voltage inputs have
been disconnected, such as load-sharing (linkage
of DC intermediate circuit).Using CD 302 Compressor Drives™: wait at least 15 minutes.
Shorter time is allowed only if indicated on the
nameplate for the specific unit.
Leakage Current
The earth leakage current from the CD 302
exceeds 3.5 mA. To ensure that the earth cable
has a good mechanical connection to the earth
connection (terminal 95), the cable cross section
must be at least 10 mm
wires terminated separately.
2
or 2 times rated earth
Residual Current Device
This product can cause a D.C. current in the
protective conductor. Where a residual current
device (RCD) is used for extra protection, only an
RCD of Type B (time delayed) shall be used on the
supply side of this product. See also RCD Application Note MN.90.GX.02.Protective earthing of the
CD 302 and the use of RCD.s must always follow
national and local regulations.
IT Mains
Do not connect 400 V frequency converters
with RFI-filters to mains supplies with a Voltage
between phase and earth of more than 440 V. For
IT mains and delta earth (grounded leg), mains
voltage may exceed 440 V between phase and
earth.
Par. 14-50 RFI 1 can on CD 302 be used to disconnect the internal RFI capacitors from the RFI
filter to ground. If this is done it will reduce the RFI
performance to A2 level.
Before Commencing Repair Work
1. Disconnect CD 302 from mains
2. Disconnect DC bus terminals 88 and 89
3. Wait for discharge of the DC-link. See period of
time on the warning label.
4. Remove motor cable
Avoid Unintended Start
While CD 302 is connected to mains, the motor
can be started/stopped using digital commands,
bus commands, references or via the Local
Control Panel (LCP).
• Disconnect the CD 302 from mains whenever
personal safety considerations make it necessary
to avoid unintended start.
• To avoid unintended start, always activate the
[OFF] key before changing parameters.
• An electronic fault, temporary overload, a fault
in the mains supply, or lost motor connection
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Instructions
may cause a stopped motor to start. CD 302 with
Safe Stop provides a certain degree of protection against such unintended start, if the Safe
Stop Terminal 37 is on low voltage level or disconnected.
Safe Stop of CD 302
The CD 302 can perform the safety function Safe
Torque Off (As defined by draft CD IEC 61800-5-
2) or Stop Category 0 (as defined in EN 60204-1).
It is designed and approved suitable for the requirements of Safety Category 3 in EN 954-1.
This functionality is called Safe Stop. Prior to integration and use of Safe Stop in an installation, a
thorough risk analysis on the installation must
be carried out in order to determine whether the
Safe Stop functionality and safety category are
appropriate and sufficient. In order to install and
use the Safe Stop function in accordance with the
requirements of Safety Category 3 in EN 954-1,
the related information and instructions of the
CD 302 Design Guide must be followed!
The information and instructions of the Operating Instructions are not sufficient for a correct
and safe use of the Safe Stop functionality!
General Specifications
Mains supply (L1, L2, L3)
• Supply voltage: 200-240 V ±10%
• Supply voltage: 380-480 V ±10%
• Supply voltage: 525-600 V ±10%
• Supply frequency: 50/60 Hz
• Maximbalance temporary between mains
phases: 3.0 % of rated supply voltage
• True Power Factor (λ): ≥ 0.9 nominal at rated
load
• Displacement Power Factor (cos φ) near unity:
(> 0.98)
• Switching on input supply L1, L2, L3 (powerups) ≤ 7.5 kW: maximum 2 times/min.
• Switching on input supply L1, L2, L3 (powerups) ≥ 11 kW: maximum 1 time/min.
• Environment according to EN60664-1: overvoltage category III/pollution degree 2
The unit is suitable for use on a circuit capable of
delivering not more than 100.000 RMS symmetrical Amperes, 240/500/600 V maximum.
Motor compressor output (U, V, W)
• Output voltage: 0 - 100% of supply voltage
• Switching on output: see param number 14-01
in table page 28.
Digital inputs
• Voltage level: 0 - 24 V DC
• Voltage level, logic.0. PNP: < 5 V DC
• Voltage level, logic.1. PNP: > 10 V DC
• Voltage level, logic .0. NPN2): > 19 V DC
• Voltage level, logic .1. NPN2): < 14 V DC
• Maximum voltage on input: 28 V DC
• Input resistance, Ri: approx. 4 kΩ
Safe stop Terminal 37
Terminal 37 is fixed PNP logic
• Voltage level: 0 - 24 V DC
• Voltage level, logic.0. PNP: < 4 V DC
• Voltage level, logic.1. PNP: >20 V DC
• Nominal input current at 24 V: 50 mA rms
• Nominal input current at 20 V: 60 mA rms
• Input capacitance: 400 nF
All digital inputs are galvanically isolated from
the supply voltage (PELV) and other high-voltage
terminals.
1) Terminals 27 and 29 can also be programmed
as output.
2) Except safe stop input Terminal 37.
3) Terminal 37 can only be used as safe stop input.
Terminal 37 is suitable for category 3 installations
according to EN 954-1 (safe stop according to
category 0 EN 60204-1) as required by the EU
Machinery Directive 98/37/EC. Terminal 37 and
the Safe Stop function are designed in conformance with EN 60204-1, EN 50178, EN 61800-2,
EN 61800-3, and EN 954-1. For correct and safe
use of the Safe Stop function follow the related
information and instructions in the Design Guide.
Analog inputs
• Number of analog inputs: 2
• Terminal number: 53, 54
• Modes: Voltage or current
• Mode select: Switch S201 and switch S202
• Voltage mode: Switch S201/switch S202 = OFF
(U)
• Voltage level: -10 to +10 V (scaleable)
• Input resistance, Ri: approx. 10 kΩ
• Max. voltage: ± 20 V
• Current mode: Switch S201/switch S202 = ON
(I)
• Current level: 0/4 to 20 mA (scaleable)
• Input resistance, Ri: approx. 200 Ω
• Max. current: 30 mA
• Resolution for analog inputs: 10 bit (+ sign)
• Accuracy of analog inputs: Max. error 0.5% of
full scale
• Bandwidth: 100 Hz
The analog inputs are galvanically isolated from
the supply voltage (PELV) and other high-voltage
terminals.
Digital output
• Programmable digital/pulse outputs: 2
• Terminal number: 27, 29
• Voltage level at digital/frequency output: 0 - 24
V
• Max. output current (sink or source): 40 mA
• Max. load at frequency output: 1 kΩ
• Max. capacitive load at frequency output: 10 nF
• Minimum output frequency at frequency
output: 0 Hz
• Maximum output frequency at frequency
output: 32 kHz
• Accuracy of frequency output: Max. error: 0.1 %
of full scale
• Resolution of frequency outputs: 12 bit
1) Terminal 27 and 29 can also be programmed as
input.
The digital output is galvanically isolated from the
supply voltage (PELV) and other high-voltage terminals.
Analog output
• Number of programmable analog outputs: 1
• Terminal number: 42
• Current range at analog output: 0/4 - 20 mA
• Max. load to common at analog output: 500 Ω
• Accuracy on analog output: Max. error: 0.5 % of
full scale
• Resolution on analog output: 12 bit
The analog output is galvanically isolated from
the supply voltage (PELV) and other high-voltage
terminals.
Control card, 24 V DC output
• Terminal number: 12, 13
• Max. load: 200 mA
The 24 V DC supply is galvanically isolated from
the supply voltage (PELV), but has the same po-
tential as the analog and digital inputs and outputs.
Control card, 10 V DC output
• Terminal number: 50
• Output voltage: 10.5 V ±0.5 V
• Max. load: 15 mA
The 10 V DC supply is galvanically isolated from
the supply voltage (PELV) and other high-voltage
terminals.
Control card, RS 485 serial communication
• Terminal number: 68 (P,TX+, RX+), 69 (N,TX-, RX-)
• Terminal number 61: Common for terminals 68
and 69
The RS 485 serial communication circuit is functionally separated from other central circuits and
galvanically isolated from the supplier voltage
(PELV).
Control card, USB serial communication
• USB standard: 1.1 (Full speed)
• USB plug: USB type B .device. plug
Connection to PC is carried out via a standard
host/device USB cable.
The USB connection is galvanically isolated from
the supply voltage (PELV) and other high-voltage
terminals. The USB ground connection is not
galvanically isolated from protection earth. Use
only isolated laptop as PC connection to the USB
connector on CD 302 drive.
Relay outputs
• Programmable relay outputs: 2
• Relay 01 Terminal number: 1-3 (break),1-2
(make)
• Max. terminal load (AC-1)1) on 1-3 (NC), 1-2
(NO) (Resistive load): 240 V AC, 2 A
• Max. terminal load (AC-15)1) (Inductive load @
cosφ 0.4): 240 V AC, 0.2 A
• Max. terminal load (DC-1)1) on 1-2 (NO), 1-3
(NC) (Resistive load): 60 V DC, 1A
• Max. terminal load (DC-13)1) (Inductive load):
24 V DC, 0.1A
• Relay 02 (CD 302 only) Terminal number: 4-6
(break), 4-5 (make)
• Max. terminal load (AC-1)1) on 4-5 (NO)
(Resistive load): 400 V AC, 2 A
• Max. terminal load (AC-15)1) on 4-5 (NO)
(Inductive load @ cosφ 0.4): 240 V AC, 0.2 A
• Max. terminal load (DC-1)1) on 4-5 (NO)
(Resistive load): 80 V DC, 2 A
How to install
Mechanical Installation
Find the following parts included in the CD302
Accessory Bag.
• Accessory Bag ≤ 7.5 kW
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Instructions
•Accessory Bag ≤ 7.5 kW, IP55 • Accessory Bag 11 – 22 kW
Mechanical mounting
1) Drill holes in accordance with the measurements given.
2) You must provide screws suitable for the surface on which you want to mount the CD 302.
Retighten all four screws.
Mechanical Dimension
CD 302 IP20 allows side-by-side installation.
Because of the need for cooling, there must be a
minimum of 100 mm free air passage above and
below the CD 302.
The back wall must always be solid. All CD302 are
equiped of a back metal plate to garantee proper
heat exchanger ventilation. Never remove this
metal sheet.
Safety Requirements of Mechanical Installation
The frequency converter is cooled by means of air
circulation.
To protect the unit from overheating, it must be
ensured that the ambient temperature does not
exceed the maximum temperature stated for the
frequency converter and that the 24-hour average temperature is not exceeded. If the ambient
temperature is in the range of 45°C - 55°C, derating of the frequency converter will become relevant. The service life of the frequency converter
is reduced if derating for ambient temperature is
not taken into account.
Mechanical dimensions
Frame size A2 Frame size A3 Frame size A5 Frame size B1 Frame size B2
4.0 kW (380-480 V)
4 kW (525-600 V)
IP 20 IP 20 IP 55 IP 21 / IP 55 IP 21 / IP 55
Height of black plate A 268 mm 268 mm 420 mm 480 mm 650 mm
Distance between
mounting holes
Width of black plate B 90 mm 130 mm 242 mm 242 mm 242 mm
Distance between
mounting holes
Depth without option A/B C 205 mm 205 mm 195 mm 260 mm 260 mm
Depth with option A/B C 220 mm 220 mm 195 mm 260 mm 260 mm
a 257 mm 257 mm 402 mm 454 mm 624 mm
b 70 mm 110 mm 215 mm 210 mm 210 mm
c 8.0 mm 8.0 mm 8.25 mm 12 mm 12 mm
d ø 11 mm ø 11 mm ø 12 mm ø 19 mm ø 19 mm
e ø 5.5 mm ø 5.5 mm ø 6.5 mm ø 9 mm ø 9 mm
f 9 mm 9 mm 9 mm 9 mm 9 mm
3.0 kW (200-240 V)
5.5 - 7.5 kW (380-480 V)
5.5 - 7.5 kW (525-600 V)
Screw holes
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4.0 kW (200-240 V)
4.0 - 7.5 kW (380-480 V)
Height
Width
Depth
5.5 - 7.5 kW (200-240 V)
11-15 kW (380-480 V)
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11kW (200-240 V)
18.5-22 kW (380-480 V)
Instructions
Electrical installation
Cables general
Always comply with national and local regulations on cable cross-sections.
Tightening-up Torque
CD size Cable for: Tightening
up torque
3-7.5 kW Line, load sharing motor
Compressor cable
11-22 kW Line, load sharing motor
compressor cable
11-22 kW Motor compressor cable 1.8 Nm
Relay 0.5 - 0.6 Nm
Earth 2 - 3 Nm
1.8 Nm
1.8 Nm
• Removal of knockouts for extra cables
- Remove cable entry from the frequency converter (Avoiding foreign parts in the frequency
converter when removing knockouts)
- Cable entry has to be supported around the
knockout you intend to remove.
- The knockout can now be removed with a
strong mandrel and a hammer.
- Remove burrs from the hole.
- Mount Cable entry on frequency converter.
• Connection to Mains and Earthing
How to connect to mains and earthing (A2 and
A3 enclosure).
- Make sure the CD 302 is properly earthed.
Connect to earth connection (terminal 95). Use
screw from the accessory bag.
- Place plug connector 91, 92, 93 from the accessory bag onto the terminals labelled MAINS at the
bottom of CD302.
- Connect mains wires to the mains plug connector.
Connection to Mains and Earthing
How to connect to mains and earthing (B1 and
B2 enclosure)
• IT Mains
Check that mains voltage corresponds to the
mains voltage of the CD302 name plate.
L1, L2, L3 mains have to be connected preferably
clockwise direction
3 Phase
Power
Input
91 (L1)
92 (L2)
93 (L3)
95 PE
• Motor compressor connection
Motor compressor cable must be screened / armoured. If an unscreened / unarmoured cable is
used, some EMC requirements are not complied
with. For more information, see EMC specifications.
- Fasten decoupling plate to the bottom of CD302
with screws and washers from the accessory bag.
- Attach motor compressor cable to terminals 96
(U), 97 (V), 98 (W).
- Connect to earth connection (terminal 99) on
decoupling plate with screws from the accessory
bag.
- Insert terminals 96 (U), 97 (V ), 98 (W) and motor
compressor cable to terminals labelled MOTOR.
Fasten screened cable to decoupling plate with
screws and washers from the accessory bag.
U, V, W for motor compressor need to be clockwise
connected. Note that VTZ compressors can rotate
on both directions, but when used in manifolded
sytems all compressors must have the same rotation direction to avoid vibration interferences.
≤7.5 kW IP 55
11 - 22 kW IP 21/55
≤7.5 kW IP 20
• Motor compressors cables
Correct dimensioning of motor compressor cable
cross-section and length is described in the application manual.
- Use a screened/armoured motor compressor
cable to comply with EMC emission specifications.
- Keep the motor compressor cable as short as
possible to reduce the noise level and leakage
currents.
- Connect the motor compressor cable screen to
both the decoupling plate of the CD302 and to
the metal cabinet of the motor compressor.
- Make the screen connections with the largest
possible surface area (cable clamp). This is done
by using the supplied installation devices in the
CD302.
• Electrical installation of motor compressor
cables
- Screening of cables :
Avoid installation with twisted screen ends (pigtails). They spoil the screening effect at higher
frequencies. If it is necessary to break the screen
to install a motor compressor isolator or motor
compressor contactor, the screen must be continued at the lowest possible HF impedance.
- Cable length and cross-section :
The frequency converter has been tested with a
given length of cable and a given cross-section
of that cable. If the cross-section is increased, the
cable capacitance - and thus the leakage current
- may increase, and the cable length must be reduced correspondingly.
- Switching frequency : The switching frequency
is factory set at 3.5 kHz.
- Aluminium conductors : Aluminium conduc-
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130BA012.11
Instructions
tors are not recommended. Terminals can accept
aluminium conductors but the conductor surface has to be clean and the oxidation must be
removed and sealed by neutral acid free Vase-
• Fuses
- Branch circuit protection:
In order to protect the installation against electrical and fire hazard, all branch circuits in an
installation, switch gear, machines etc., must be
shortcircuit and overcurrent protected according
to the national/international regulations.
- Short circuit protection:
The frequency converter must be protected
line grease before the conductor is connected.
Furthermore, the terminal screw must be retightened after two days due to the softness of the
aluminium. It is crucial to keep the connection a
against short-circuit to avoid electrical or fire
hazard. Danfoss recommends using the fuses
mentioned below to protect service personnel or
other equipment in case of an internal failure in
the drive. The frequency converter provides full
short circuit protection in case of a short-circuit
on the motor compressor output.
- Over current protection:
Provide overload protection to avoid fire hazard
gas tight joint, otherwise the aluminium surface
will oxidize again.
due to overheating of the cables in the installation. The frequency converter is equipped with
an internal over current protection that can be
used for upstream overload protection (UL-applications excluded). See par. 4-18. Moreover, fuses
or circuit breakers can be used to provide the
over current protection in the installation. Over
current protection must always be carried out
according to national regulations.
- UL compliance (380-480 V, 525-600 V)
CD 302 Bussmann SIBA Littel fuse Ferraz- Shawmut
kW Type RK1 Type J Type T Type RK1 Type K1 Type CC Type RK1
4.0 KTS-R20 JKS-20 JJS-20 5017906-020 KLS-R20 ATM-R20 A6K-20R
5.5-7.5 KTS-R30 JKS-30 JJS-30 5012406-32 KLS-R30 ATM-R30 A6K-30R
11.0 KTS-R40 JKS-40 JJS-40 5014006-040 KLS-R40 A6K-40R
15.0 KTS-R50 JKS-50 JJS-50 5014006-50 KLS-R50 A6K-50R
18.0 KTS-R60 JKS-60 JJS-60 5014006-63 KLS-R60 A6K-60R
22.0 KTS-R80 JKS-80 JJS-80 100 KLS-R80 KLS-R80 A6K-80R
- Non UL compliance :
If UL/cUL is not to be complied with, we recommend using the following fuses, which will ensure compliance with EN50178.In case of malfunction, not following the
recommendation may result in unnecessary damage of the frequency converter.
CD 302 Max. fuse size Voltage Type
3K0-3K7 32A* 200-240 V type gG
3K0-4K0 20A* 380-480 V type gG
5K5-7K5 32A* 380-480 V type gG
11K 63A* 380-480 V type gG
15K 63A* 380-480 V type gG
18K 63A* 380-480 V type gG
22K 80A* 380-480 V type gG
* : Max. fuses - see national/ international regulations for selecting an applicable fuse size.
• Electrical motor compressor protection
The electrical motor compressor protection is
fully provided by the CD302 frequency converter.
- CD302 makes through an Electronic current
measurement anti-overload and lock-rotor motor
compressor protection (see description in the
application manual).
- The frequency converter is protected against
short-circuits on compressor terminals U, V, W.
- If a mains phase is missing, the frequency
converter trips or issues a warning (depending on
the load).
- If a motor compressor phase is missing, the
frequency converter trips.
- The frequency converter is protected against
earth faults on compressor terminals U, V, W.
- The frequency converter is protected against
short circuits on compressor terminals U, V, W.
- Monitoring of the intermediate circuit voltage
ensures that the frequency converter trips if the
intermediate circuit voltage is too low or too high.
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• Access to Control Terminals
3
4
2
1
A1, A2 and A3 enclosures A5, B1 and B2 enclosures 1. 10 pole plug digital I/O
2. 3 pole plug RS485 Bus
3. 6 pole analog I/O
4. USB Connection
AN000086420674en-000201 | 5
Instructions
To mount the cable to the terminal:
1. Strip isolation of 9-10 mm
2. Insert a screw driver in the square hole.
3. Insert the cable in the adjacent circular hole.
4. Remove the screw driver. The cable is now
mounted to the terminal.
To remove the cable from the terminal:
1. Insert a screw driver in the square hole.
2. Pull out the cable.
• Basic Wiring Example
1. Mount terminals from the accessory bag to
the front of the CD 302.
2. Connect terminals 18, 27 and 37 to +24 V (terminal 12/13)
Default settings:
18 = start
27 = coast inverse
37 = safe stop inverse
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130BA025.17
91 (L1)
92 (L2)
93 (L3)
PE
88 (-)
89 (+)
50 (+10 V OUT)
53 (A IN)
54 (A IN)
55 (COM A IN)
0/4-20 mA
12 (+24V OUT)
13 (+24V OUT)
37 (D IN)
18 (D IN)
20
(COM D IN)
10Vdc
15mA 130/200mA
+- +-
(U) 96
(V) 97
(W) 98
(PE) 99
(COM A OUT) 39
(A OUT) 42
(P RS-485) 68
(N RS-485) 69
(COM RS-485) 61
0V
5V
S801
0/4-20 mA
RS-485
RS-485
03
+10Vdc
-10Vdc -
+10Vdc
+10Vdc
0/4-20 mA
-10Vdc -
240Vac, 2A
24Vdc
02
01
05
04
06
240Vac, 2A
24V (NPN)
0V (PNP)
0V (PNP)
24V (NPN)
19 (D IN)
24V (NPN)
0V (PNP)
27
24V
0V
(D IN/OUT)
0V (PNP)
24V (NPN)
(D IN/OUT)
0V
24V
29
24V (NPN)
0V (PNP)
0V (PNP)
24V (NPN)
33 (D IN)
32 (D IN)
12
ON
S201
ON
21
S202
ON/I=0-20mA
OFF/U=0-10V
95
400Vac, 2A
P 5-00
21
ON
S801
(R+) 82
(R-) 81
*
*
*
3 Phase
power
input
DC bus
Switch Mode
Power Supply
Motor
Analog Output
Interface
relay1
relay2
(PNP) = Source
(NPN) = Sink
ON=Terminated
OFF=Open
Brake
resistor
Instructions
Diagram showing all electrical terminals.
Terminal 37 is the input to be used for Safe Stop.
Very long control cables and analog signals may
in rare cases and depending on installation result
in 50/60 Hz earth loops due to noise from mains
supply cables.
If this occurs, you may have to break the screen
or insert a 100 nF capacitor between screen and
chassis.
The digital and analog in- and outputs must be
connected separately to the CD302 common
inputs (terminal 20, 55, 39) to avoid ground currents from both groups to affect other groups.
For example, switching on the digital input may
disturb the analog input signal.
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AN000086420674en-000201 | 7
SPS etc.
SPS etc.
SPS etc.
Min. 16mm
2
Ausgleichskabel
SPS etc.
PE
FC
PE
130BA051.11
PE PE
FC
PE PE
FC
100nF
PE
FC
69
FC
PE PE
PE
68
61
68
69
FC
PE
a
b
c
d
e
Instructions
- Control cables must be screened/armoured.
Use a clamp from the accessory bag to connect
the screen to the CD 302 decoupling plate for
control cables.
Generally speaking, control cables must be
braided screened/armoured and the screen must
be connected by means of a cable clamp at both
ends to the metal cabinet of the unit.
The drawing indicates how correct earthing is
carried out and what to do if in doubt.
a. Correct earthing
Control cables and cables for serial communication must be fitted with cable clamps at both ends
to ensure the best possible electrical contact.
b. Wrong earthing
Do not use twisted cable ends (pigtails). They increase the screen impedance at high frequencies.
c. Protection with respect to earth potential
between PLC(Program Logic Controller) and
CD 302
If the earth potential between the frequency
converter and the PLC (etc.) is different, electric
noise may occur that will disturb the entire system. Solve this problem by fitting an equalising
cable, next to the control cable. Minimum cable
cross-section: 16mm2.
d. For 50/60 Hz earth loops
If very long control cables are used, 50/60 Hz
earth loops may occur. Solve this problem by
connecting one end of the screen to earth via a
100nF capacitor (keeping leads short).
e. Cables for serial communication
Eliminate low-frequency noise currents between
two frequency converters by connecting one
end of the screen to terminal 61. This terminal
is connected to earth via an internal RC link. Use
twisted-pair cables to reduce the differential
mode interference between the conductors.
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• Electrical Installation - EMC protection
The following is a guideline to good engineering
practice when installing frequency converters.
Follow these guidelines to comply with EN
61800-3 First environment. If the installation is
in EN 61800-3 Second environment, i.e. industrial networks, or in an installation with its own
transformer, deviation from these guidelines is
allowed but not recommended. See also paragraphs CE Labelling, General Aspects of EMC Emission and EMC Test Results.
Good engineering practice to ensure EMC-correct electrical installation:
- Use only braided screened/armoured motor
compressor cables and braided screened/armoured control cables. The screen should provide a
minimum coverage of 80%. The screen material
must be metal, not limited to but typically copper, aluminium, steel or lead. There are no special
requirements for the mains cable.
- Installations using rigid metal conduits are not
required to use screened cable, but the motor
compressor cable must be installed in conduit
separate from the control and mains cables. Full
connection of the conduit from the drive to the
motor compressor is required. The EMC performance of flexible conduits varies a lot and information from the manufacturer must be obtained.
- Connect the screen/armour/conduit to earth at
both ends for motor compressor cables as well as
for control cables.
In some cases, it is not possible to connect the
• Safe Stop Installation
To carry out an installation of a Category 0 Stop
(EN60204) in conformance with Safety Category
3 (EN954-1), follow these instructions:
1. The bridge ( jumper) between Terminal 37 and
24 V DC of CD 302 must be removed. Cutting or
breaking the jumper is not sufficient. Remove it
entirely to avoid short-circuiting. See jumper on
illustration.
2. Connect terminal 37 to 24 V DC by a short-circuit protected cable. The 24 V DC voltage supply
must be interruptible by an EN954-1 Category 3
circuit interrupt device. If the interrupt device and
the frequency converter are placed in the same
installation panel, you can use a regular cable
instead of a protected one.
screen in both ends. If so, connect the screen
at the frequency converter. See also Earthing of
Braided Screened/Armoured Control Cables.
- Avoid terminating the screen/armour with
twisted ends (pigtails). It increases the high
frequency impedance of the screen, which reduces its effectiveness at high frequencies. Use
low impedance cable clamps or EMC cable glands
instead.
- Avoid using unscreened/unarmoured motor
compressor or control cables inside cabinets housing the drive(s), whenever this can be avoided.
Leave the screen as close to the connectors as
possible.
The illustration shows an example of an EMC-correct electrical installation of an IP 20 frequency
converter.
The frequency converter is fitted in an installation
cabinet with an output contactor and connected
to a PLC, which is installed in a separate cabinet.
© Danfoss | DCS (CC) | 2019.04
Instructions
Other ways of doing the installation may have just
as good an EMC performance, provided the above
guide lines to engineering practice are followed.
• EMC Correct Installation of an IP20 CD302
If the installation is not carried out according
to the guideline and if unscreened cables and
control wires are used, some emission require-
ments are not complied with, although the immunity requirements are fulfilled. See the paragraph EMC test results.
• Safety earth connection
The frequency converter has a high leakage current and must be earthed appropriately for safety
reasons acording to EN 50178.
© Danfoss | DCS (CC) | 2019.04
The earth leakage current from the frequency
converter exceeds 3.5 mA. To ensure a good mechanical connection from the earth cable to the
earth connection (terminal 95), the cable cross-
section must be at least 10 mm2 or 2 rated earth
wires terminated separately.
AN000086420674en-000201 | 9
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