Danfoss CDS 801 Operating guide
MAKING MODERN LIVING POSSIBLE
OOperating Instructions
VLTp Inverter Scroll CDS 801
Contents
Contents
VLT® Inverter Scroll CDS 801 Operating Instructions
1 General
1.1 Coverage
1.1.1 Disclaimer 4
1.1.2 Coverage 4
1.2 Safety Instructions
1.3 Approvals
1.4 General Warning
1.5 Disposal Instruction
1.6 Before Commencing Repair Work
1.7 ESD Precautions
1.8 Product Identification
1.9 Unpacking the Drive
1.10 Table of Abbreviations
2 Mechanical Installation
2.1 Dimensions and Weight
2.2 Installation Orientation and Clearances
2.2.1 Surface Mounting 9
4
4
4
4
5
5
5
5
5
5
6
7
7
9
2.2.2 Structural Mounting 11
2.3 Air Circulation/Cooling
2.4 Condensation and Dripping Water
2.5 Vibration and Mechanical Resonances
3 Electrical Installation
3.1 Electrical Connection in General
3.2 Tightening Torque
3.3 Cable Quality and Dimensioning
3.4 Fuses/Circuit Breakers
3.5 EMC Correct Installation
3.6 Electrical Connections
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
12
12
12
13
13
13
13
13
14
15
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
MG10V402 - VLT® is a registered Danfoss trademark 1
Contents
VLT® Inverter Scroll CDS 801 Operating Instructions
3.6.11 Overview Wiring Diagram 22
4 Serial Communication (Modbus RTU)
5 Commissioning
5.1 Initial Configuration of the Performer VSD sub-system
5.2 Drive Setup
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
5.4 Crankcase Heating
5.5 Ambient Temperature Source
5.6 Pressure sensor scaling
5.7 Normal Operation
6 Embedded Application Controller “Thermo Control”
6.1 Introduction
6.2 Applications
6.2.1 Generic AC 31
25
27
27
27
29
29
29
30
30
31
31
31
6.2.2 Generic AC/HP (Reversible) 32
6.2.3 Ground Source Heat Pump (Reversible) 33
6.3 Application Controller
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
33
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
2 MG10V402 - VLT® is a registered Danfoss trademark
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)
7 Fault Conditions, Messages and Causes
8 Troubleshooting
9 Specifications
10 Special Operating Conditions
11 Maintenance
11.1 Replacement of Internal Cooling Fan
11.2 Cleaning
12 Service and Spare Parts
Index
42
44
47
48
50
51
51
51
52
53
MG10V402 - VLT® is a registered Danfoss trademark 3
General
VLT® Inverter Scroll CDS 801 Operating Instructions
11
1 General
1.1 Coverage
The earth leakage current exceeds 3.5 mA
•
A stop command does not disconnect power
•
from the drive
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.
Coverage
1.1.2
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.
1.2
Safety Instructions
1.3 Approvals
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
permissible system impedance Z
≥
100 A per phase or a maximum
= 0.1892
MAX
Ω
1.2.1 High Voltage Warning
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 over-
•
current according to national and local
regulations
4 MG10V402 - VLT® is a registered Danfoss trademark
130ZB121.10
IP00/CHASSIS -25
C/ -13 F to 52 C/125 F
PERFORMER
MADE IN DENMARK
R
CDS801 Variable Speed Drive
P/N: 176L7002 S/N: 010199D082
20 kW/5 TR cooling capacity
IN: 1x208-230V 50-60Hz 33A 6,7 kW
OUT: 3x270V 45-210Hz 33A
VSD
o o o o
CAUTION:
See manual before use.
Lire le manual avant utilisation
WARNING:
Stored charge, wait 5 min. before service.
Energia aimacenada, asperar 5 min. para descaega antes de lisar.
E337256
* 1 7 6 L 7 0 0 2 0 1 0 1 9 9 D 0 6 2 *
Charge stockée, attendre 5 min. avant l’emploi.
Leer manual antec deusar.
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.
1 1
1.6 Before 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.
1.7 ESD 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).
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.
1.5
Disposal 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.
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!
MG10V402 - VLT® is a registered Danfoss trademark 5
General
VLT® Inverter Scroll CDS 801 Operating Instructions
11
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
6 MG10V402 - VLT® is a registered Danfoss trademark
196 mm/7.7 in
374 mm/
14.7 in
175ZB032.13
394 mm/15.5 in
216 mm/8.5 in
255 mm/10 in
98 mm/
3.8 in
Mechanical Installation
2 Mechanical Installation
2.1 Dimensions and Weight
VLT® Inverter Scroll CDS 801 Operating Instructions
2 2
Illustration 2.1 Dimensions
MG10V402 - VLT® is a registered Danfoss trademark 7
236 mm/9.3 in
216 mm/8.5 in 394 mm/15.5 in
180 mm/
7.1 in
98 mm/
3.8 in
175ZB031.13
255 mm/10 in
180 mm/
7.1 in
Mechanical Installation
VLT® Inverter Scroll CDS 801 Operating Instructions
22
Illustration 2.2 Dimensions
Mounting holes: ¼ inch, Ø 6 mm
Weight: 10.3 lbs/5.5 kg
8 MG10V402 - VLT® is a registered Danfoss trademark
175ZB036.10
175ZB037.10
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.
2 2
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.
Illustration 2.3 Horizontal Orientation
Illustration 2.4 Vertical Orientation
MG10V402 - VLT® is a registered Danfoss trademark 9
175ZB038.12
Mechanical Installation
To avoid insufficient cooling, do not install the drive with
the cooling fan in the top, see Illustration 2.5.
VLT® Inverter Scroll CDS 801 Operating Instructions
22
Illustration 2.5 Wrong Drive Orientation
10 MG10V402 - VLT® is a registered Danfoss trademark
175ZB041.10
175ZB042.10
Mechanical Installation
2.2.2 Structural Mounting
VLT® Inverter Scroll CDS 801 Operating Instructions
The drive can be integrated in any kind of mechanical
structure of air conditioning equipment Illustration 2.6 and
Illustration 2.7.
2 2
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
MG10V402 - VLT® is a registered Danfoss trademark 11
175ZB043.10
Mechanical Installation
VLT® Inverter Scroll CDS 801 Operating Instructions
2.3 Air Circulation/Cooling
2.5
The drive must be installed in a way that allows for free
22
airflow. However short circuiting the airflow (warm air reentering 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.
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.
12 MG10V402 - VLT® is a registered Danfoss trademark
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
Proper temperature rating of the cable must be observed.
In installations with ambient temperatures above 30 °C
maximum current derating applies, therefore hightemperature 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.
3
3
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
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.
3 t unit 30 A
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”).
MG10V402 - VLT® is a registered Danfoss trademark 13
Electrical Installation
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
VLT® Inverter Scroll CDS 801 Operating Instructions
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 de-
•
coupling 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.
14 MG10V402 - VLT® is a registered Danfoss trademark
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