Danfoss CDS 801 Operating guide

MAKING MODERN LIVING POSSIBLE

Operating Instructions

VLTp Inverter Scroll CDS 801

Contents

VLT® Inverter Scroll CDS 801 Operating Instructions

Contents

1 General	4
1.1 Coverage	4
1.1.1 Disclaimer	4
1.1.2 Coverage	4
1.2 Safety Instructions	4
1.3 Approvals	4
1.4 General Warning	5
1.5 Disposal Instruction	5
1.6 Before Commencing Repair Work	5
1.7 ESD Precautions	5
1.8 Product Identification	5
1.9 Unpacking the Drive	5
1.10 Table of Abbreviations	6
2 Mechanical Installation	7
2.1 Dimensions and Weight	7
2.2 Installation Orientation and Clearances	9
2.2.1 Surface Mounting	9
2.2.2 Structural Mounting	11
2.3 Air Circulation/Cooling	12
2.4 Condensation and Dripping Water	12
2.5 Vibration and Mechanical Resonances	12
3 Electrical Installation	13
3.1 Electrical Connection in General	13
3.2 Tightening Torque	13
3.3 Cable Quality and Dimensioning	13
3.4 Fuses/Circuit Breakers	13
3.5 EMC Correct Installation	14
3.6 Electrical Connections	15
3.6.1 Routing of Motor and Supply Cable	15
3.6.2 Power Supply Connection (Mains)	16
3.6.3 Motor (Compressor) Connection	16
3.6.4 Sensor Connections	18
3.6.5 4-way Reversing Valve Connection	18
3.6.6 Condenser Fan Motor Control Connection (EXT_FAN)	18
3.6.7 EEV Controller (HP Mode) Connection (EEV_2)	18
3.6.8 Serial Communication Cable Connection	19
3.6.9 Connector Specification	20
3.6.10 Allocation of Connector Pins	21

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Contents

VLT® Inverter Scroll CDS 801 Operating Instructions

3.6.11 Overview Wiring Diagram	22
4 Serial Communication (Modbus RTU)	25
5 Commissioning	27
5.1 Initial Configuration of the Performer VSD sub-system	27
5.2 Drive Setup	27
5.2.1 Drive Parameters
(Modbus Registers, node 162)	27
5.2.2 Drive Parameters
(Modbus Registers, node 163)	28
5.3 Condenser Fan Speed Reference Output	29
5.4 Crankcase Heating	29
5.5 Ambient Temperature Source	29
5.6 Pressure sensor scaling	30
5.7 Normal Operation	30
6 Embedded Application Controller “Thermo Control”	31
6.1 Introduction	31
6.2 Applications	31
6.2.1 Generic AC	31
6.2.2 Generic AC/HP (Reversible)	32
6.2.3 Ground Source Heat Pump (Reversible)	33
6.3 Application Controller	33
6.3.1 Introduction	33
6.3.2 System Modes	33
6.3.2.1 Off	33
6.3.2.2 AC	33
6.3.2.3 HP	34
6.3.2.4 Defrost	34
6.3.3 Compressor Capacity Control	34
6.3.3.1 Single Loop Room Temperature Control	35
6.3.3.2 Open Loop/ External Speed Control	35
6.3.4 Condensing Pressure Control	36
6.3.4.1 AC Mode	36
6.3.4.2 HP Mode	38
6.3.4.3 Defrost Mode	39
6.3.5 Auxiliary Functions	39
6.3.5.1 Start-Up Sequence	39
6.3.5.2 Restart Timer	40
6.3.5.3 Compressor Safety Envelope	40
6.3.5.4 Oil Return	40

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Contents

VLT® Inverter Scroll CDS 801 Operating Instructions

6.3.5.5 Derating	40
6.3.5.6 Discharge temperature cut out	41
6.3.5.7 Max Suction Pressure (MOP)	41
6.3.5.8 Frequency Cancelation	41
6.3.5.9 System Status	41
6.4 Thermo Controller Register Overview (Node 162)	42
7 Fault Conditions, Messages and Causes	44
8 Troubleshooting	47
9 Specifications	48
10 Special Operating Conditions	50
11 Maintenance	51
11.1 Replacement of Internal Cooling Fan	51
11.2 Cleaning	51
12 Service and Spare Parts	52
Index	53

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General VLT® Inverter Scroll CDS 801 Operating Instructions

1	1	1 General

1.1 Coverage

1.1.1 Disclaimer

Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed. All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.

1.1.2 Coverage

This instruction covers 3 different drive sizes with single phase 208-240 V power supply matching compressor sizes for

-13 kW/3 t cooling capacity

-16 kW/4 t cooling capacity

-20 kW/5 t cooling capacity from software version 1.09.

1.2Safety Instructions 1.2.1 High Voltage Warning

•The earth leakage current exceeds 3.5 mA

•A stop command does not disconnect power from the drive

1.3Approvals

The drive has been designed/approved in accordance with the following standards:

Safety	UL/EN 60335-1, 60335-2-34 (UL 984)
Household	UL/EN 60730
Industrial	EN 61800-3 (frequency converter standard)
Software	UL 1998 cl. B
Polymerics	UL 746 C
EMC	With ferrite: EN 55011 cl. A, EN 55014
Harmonics	EN 61000-3-12, IEEE 519-1992
Surge	EN 61642-12
Immunity	EN 61000-6
Transient	EN 61000-4
Corrosion	UL 50E, ISO 9223, EN 61000-5-1, ASTM B117
Environment	IEC 60721-3-3 cl. 3K4
Enclosure	NEMA 250-2003

Table 1.1 Standards Complied to

The equipment complies with the flicker requirement according to IEC/EN61000-3-11 at 230 V nominal voltage under the condition that the service current capacity is ≥100 A per phase or a maximum permissible system impedance ZMAX = 0.1892 Ω

WARNING

The voltage of the variable speed drive is dangerous whenever it is connected to mains. Incorrect installation of the variable speed drive 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.

1.2.2 Safety Instructions

•

•

•

•

Make sure the drive is properly connected to earth

Do not remove the mains connector or motor (compressor) connector while the drive is connected to power

Protect personnel against supply voltage

Protect the variable speed drive against overcurrent according to national and local regulations

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General

VLT® Inverter Scroll CDS 801 Operating Instructions

1.4 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.

Be aware that there may be high voltage on the DC link even when the LED is turned off.

Before touching any potentially live parts of the drive, wait at least 1 minute.

CAUTION

Leakage Current

The earth leakage current from the variable speed drive exceeds 3.5 mA. Grounding and bounding shall comply with UL 1995/NEC.

Residual Current Device

This product can cause a D.C. current in the protective earth, only an RCD of Type B (time delayed) shall be used in the supply side of this product. See also Application Note on RCD, MN90G.

Protective earthing of the drive and the use of RCDs must always follow national and local regulations.

WARNING

Installation in high altitudes:

At altitudes above 6000 ft (2000 m), contact Danfoss regarding SELV.

Avoid unintended start

While the variable speed drive is connected to mains, the motor (compressor) can be started/stopped using serial communication commands.

-Disconnect the frequency converter from mains whenever personal safety considerations make it necessary to avoid unintended start.

1.5Disposal Instruction

Equipment containing electrical components may not be disposed together with domestic waste.

It must be separately collected with electrical and electronic waste according to local and valid legislation.

1 1

1.6Before Commencing Repair Work

1.Disconnect the variable speed drive from mains (flip the circuit breaker or pull fuses).

2.Wait for at least 5 minutes for discharge of the DC-link capacitors.

3.Remove motor (compressor) cable.

1.7ESD Precautions

A variable speed drive is a sensible electronic device. Electrostatic discharge (ESD) can cause a malfunction or destroy the frequency converter. Do not touch components on the printed circuit board (PCB). When handling the drive make sure that necessary ESD precautions are taken, i.e. wearing wrist straps, using antistatic mats etc.

1.8 Product Identification

A product identification label is placed on the drive chassis. It carries the ordering code i.e. 76L7002. The last 3 digits of the numeric string indicate the production date, i.e. 062 means week 6 in 2012. Do not remove the identification label from the drive (loss of warranty).

PERFORMER R		VSD	<![if ! IE]> <![endif]>130ZB121.10
CDS801	Variable Speed Drive
P/N: 176L7002	S/N: 010199D082

20 kW/5 TR cooling capacit y

IN: 1x208-230V 50-60H z 33A 6,7 kW OUT: 3x270V 45-210H z 33A IP00/CHASSIS -25oC/ -13oF to 52oC/125o F

* 1 7 6 L 7 0 0 2 0 1 0 1 9 9 D 0 6 2 *

MADE IN DENMARK

E337256

CAUTION:

See manual bef ore use.

Leer manual an tec deusar.

Lire le manualavant utilisation

WARNING:

Stored charge, wait 5 min. before service.

Energia aimacenada, asperar 5 min. para descaega an tes de lisar.

Charge stockée, attendre 5 min. avant l’emploi.

Illustration 1.1 Product Identification Label

1.9 Unpacking the Drive

NOTE

To avoid damage to the drive caused by electrostatic discharge, people handling the drive should wear wrist traps for proper grounding at all time!

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General

VLT® Inverter Scroll CDS 801 Operating Instructions

1 1

1.10	Table of Abbreviations
VSD	Variable speed drive
VFD	Variable frequency drive, also used instead of VSD
EMC	Electromagnetic compatibility
RCD	Residual current device
SELV	Safety extra low voltage
ESD	Electrostatic discharge
PCB	Printed circuit board
AWG	American wire gauge
EEV	Electronic expansion valve
RTU	Remote terminal unit
OEM	Original equipment manufacturer
AC	Air-conditioning
HP	Heat pump
RLA	Rated load amperage
AOC	Application oriented controller
MOC	Motor oriented controller

Table 1.2 Abbreviations

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Mechanical Installation

VLT® Inverter Scroll CDS 801 Operating Instructions

2 Mechanical Installation

2 2

2.1 Dimensions and Weight

255 mm/10 in

98 mm/

3.8 in

216 mm/8.5 in

196 mm/7.7 in

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394 mm/15.5 in

374 mm/

14.7 in

Illustration 2.1 Dimensions

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Mechanical Installation

VLT® Inverter Scroll CDS 801 Operating Instructions

	216 mm/8.5 in	394 mm/15.5 in
2	2
	98 mm/
	3.8 in
	255 mm/10 in
	236 mm/9.3 in

180 mm/

7.1 in

180 mm/

7.1 in

Illustration 2.2 Dimensions

Mounting holes: ¼ inch, Ø 6 mm

Weight: 10.3 lbs/5.5 kg

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Mechanical Installation

VLT® Inverter Scroll CDS 801 Operating Instructions

2.2 Installation Orientation and Clearances

2.2.1 Surface Mounting

The drive can be installed horizontally (see Illustration 2.4) or vertically (see Illustration 2.3) on any plain surface with the PCB pointing towards the surface. Typically, the 6 mounting holes in the side flaps of the chassis are used for installation.

For vertical installation, the upper two mounting holes can be used as suspension holes.

NOTE

If the drive is installed on a sheet metal surface, the clearance between the drive PCB and the mounting surface must be observed. As a minimum, sheet metal gauge 22, 33/1000 inch or 1 mm should be used. If electrical contact with the mounting surface can not be avoided an additional isolation foil should be used.

NOTE

For outdoor units, do not install the drive horizontally with the PCB in the top or bottom. Water condensing on the PCB cannot be properly drained.

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2 2

Illustration 2.3 Horizontal Orientation

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Illustration 2.4 Vertical Orientation

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2 2

Mechanical Installation

VLT® Inverter Scroll CDS 801 Operating Instructions

To avoid insufficient cooling, do not install the drive with the cooling fan in the top, see Illustration 2.5.

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Illustration 2.5 Wrong Drive Orientation

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Mechanical Installation

VLT® Inverter Scroll CDS 801 Operating Instructions

2.2.2 Structural Mounting

The drive can be integrated in any kind of mechanical structure of air conditioning equipment Illustration 2.6 and

Illustration 2.7.

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Illustration 2.7 Horizontal Installation in Mechanical Structure

CAUTION

During mechanical installation of the drive make sure that no screws can touch electrical parts on the PCB. Screws touching the electrical parts on the PCB can cause personal injury and product damage.

Illustration 2.6 Vertical Installation in Mechanical Structure

2 2

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Mechanical Installation

VLT® Inverter Scroll CDS 801 Operating Instructions

2.3 Air Circulation/Cooling

The drive must be installed in a way that allows for free 2 2 airflow. However short circuiting the airflow (warm air re-

entering the drive’s cooling fan) must be avoided (see Illustration 2.8). A clearance of 5 inches (12.7 cm) must be observed in both ends of the drive chassis. Install the drive in a location where coldest possible air can be drawn into the drive, i.e. from the bottom part of an outdoor unit. Counter flow (static pressure) must not restrict the operation of the internal cooling fan of the drive.

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2.5 Vibration and Mechanical Resonances

The mechanical structure (sheet metal) carrying the drive must be designed to withstand vibration and consequently resonances induced by the compressor or condenser fan. See vibration specification for the drive further down this document.

Also refer to 6.3.5.8 Frequency Cancelation explaining the possibility to program bypass frequencies in the drive to avoid mechanical resonances of the structure.

Illustration 2.8 Wrong Drive Airflow

2.4 Condensation and Dripping Water

The printed circuit board assembly of the drive is conformally coated and thus sufficiently protected against condensation during off time. Nevertheless, the drive should not be exposed to dripping water (rain) or condensing water slung around by the condenser fan. In outdoor units, it is recommendable to install the drive in a rain proof compartment.

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Electrical Installation

VLT® Inverter Scroll CDS 801 Operating Instructions

3 Electrical Installation

3.1 Electrical Connection in General

NOTE

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

3.2 Tightening Torque

Power supply plug terminals	1.5 Nm/1.1 lbf ft
Ground screw	3.0 Nm/2.2 lbf ft
Motor plug (compressor)	1.5 Nm/1.1 lbf ft
EMC clamp for motor cable	1.5 Nm/1.1 lbf ft

Table 3.1 Tightening Torque

3.3 Cable Quality and Dimensioning

Power supply cable

There is no need for using shielded cable for the supply of the variable speed drive.

Motor cable

The cable from the drive to the compressor (motor) must be shielded to comply with EMC regulations for conducted and radiated emissions in accordance with EN 55011 class A and EN 55014 (with ferrite). A proper ground connection of the shield in both ends is essential to obtain the best suppression of emissions. See also 3.6 Electrical Connections.

Power Supply Cable Specification

Power connections must be made in accordance with local and national codes. 2-wire cable plus ground conductor, minimum AWG 10, voltage rating minimum 300 V, minimum temp. rating 105 °C/221°F

Min. circuit ampacity	3 t unit	30	A
	4 t unit	35 A
	5 t unit	40 A

Table 3.2 Power-supply Cable Specificatoin

Motor Cable Specification

Depending on the desired level of EMC compliance according to European or North American standards for radiated emissions such as EN 55014/55011 or FCC part 15, a suitable cable connection drive and compressor must be selected. It is recommended to use shielded cable under all circumstances.

Cable specification for installations in the EU:

4-wire cable with protective earth (PE) and shield (min 80% coverage), minimum cross section 4 mm2 for 13 kW units and 6 mm2 for 16 and 20 kW units, voltage rating 600 V.

Proper temperature rating of the cable must be observed. In installations with ambient temperatures above 30 °C

maximum current derating applies, therefore high- 3 3 temperature cable with 90 °C conductor temperature, e.g.

Nexans Rheyflex is recommended. Copper type cable only. Maximum cable length 2 m.

Cable specification for installations in North America: 3-wire cable, minimum cross section AWG 10, voltage rating 600 V, temperature rating 221 °F/105 °C, 2/64 moisture resistant UL style 1230 standard bare copper type. In North America, standards for radiated emission are currently not enforced. Furthermore, FCC parts 15 regulations explicitly exempt air-condition devices. Maximum cable length 7 ft. Local compressor grounding.

Min. circuit ampacity	13 kW/3 t unit	30 A
	16 kW/4 t unit	35 A
	20 kW/5 t unit	40 A

Table 3.3 Motor Cable Specification

Sensor and Transmitter Cables

Refer to the documentation provided with the Danfoss sensors and transmitters.

For serial communication connections, see 4 Serial Communication (Modbus RTU).

3.4 Fuses/Circuit Breakers

Branch circuit protection

To protect the installation against electrical and fire hazard, all branch circuits in an installation must be short-circuited and over-current protected according to national and local regulations.

Short circuit protection

Danfoss requires using the fuses mentioned in Table 3.4 to protect service personnel or other equipment in case of an internal failure in the unit or short-circuit on DC-link of the drive. The variable speed drive provides full short circuit protection in case of a short-circuit on the motor output in accordance with UL regulations.

Over-current protection

Overload protection must be provided to avoid overheating of the cables in the installation. Over-current protection must always be carried out according to national regulations (NEC Article 430 “Motors, Motor Circuits and Controllers” and NEC Article 440 “Airconditioning and refrigeration equipment”).

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		Electrical Installation	VLT® Inverter Scroll CDS 801 Operating Instructions
		Fuses
		13 kW/3 t unit 176L0767 RLA 22A	max. fuse amperage 30 A
		16 kW/4 t unit 176L0766 RLA 28A	max. fuse amperage 35 A
		20 kW/5 t unit 176L0765 RLA 33A	max. fuse amperage 40 A
3	3
		Table 3.4 Fuses

NOTE

Fuses of type class RK5 must be used in US installations.

Recommended circuit breakers

HVCR type fusible circuit breaker may be used, see rating above.

3.5 EMC Correct Installation

Follow these guidelines when compliance with EN 55011 cl. A or EN 55014 is required.

Good engineering practice to ensure EMC-correct electrical installation:

•

•

•

•

•

Use only shielded/braided screened/armored motor cables and control cables. The shield should provide a minimum coverage of 80%. The shield material must be metal, not limited to but typically copper, aluminum, steel or lead. There are no special requirements for the mains cable.

Connect the shield to ground at both ends for motor cables and control cables.

Avoid terminating the shield with twisted ends (pigtails). Such a termination increases the high frequency impedance of the screen, which reduces its effectiveness at high frequencies. Use low impedance cable clamps (delivered with the drive) and EMC glands instead.

Ensure good electrical contact between the decoupling plate and the metal chassis of the variable speed drive.

Where possible, avoid using unshielded/ unarmored motor or control cables inside cabinets housing the drive.

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