Danfoss CDS 803 Operating guide

Operating Guide

VLT® Compressor Drive CDS 803

6–30 kW

vlt-drives.danfoss.com

VLT® Compressor Drive CDS 803
Operating Guide	Contents

Contents

1 Introduction		6
1.1	Purpose of this Operating Guide	6
1.2	Additional Resources	6
	1.2.1 Supplementary Documentation	6
	1.2.2 VLT® Motion Control Tool MCT 10 Software Support	6
1.3	Manual and Software Version	6
1.4	Approvals and Certifications	6
1.5	Disposal	7
1.6	CE Declaration	8

2 Safety		10
2.1	Safety Symbols	10
2.2	Qualified Personnel	10
2.3	Safety Precautions	10

3 Installation				12
3.1	Mechanical Installation			12
	3.1.1	Side-by-side Installation		12
	3.1.2	Operating Environment		12
		3.1.2.1 Derating for Ambient Temperature and Switching Frequency		12
		3.1.2.2 Derating for Low Air Pressure and High Altitudes		12
3.2	Electrical Installation			12
	3.2.1 Electrical Installation in General			12
		3.2.1.1	Fastener Torque Ratings	12
	3.2.2 Fuses and Circuit Breakers			13
		3.2.2.1 Recommendation of Fuses and Circuit Breakers		13
	3.2.3	Electrical Wiring		14
		3.2.3.1	Wiring Schematic	14
		3.2.3.2 Terminal Overview of Enclosure Sizes H3–H5		15
		3.2.3.3 Terminal Overview of Enclosure Size H6		16
		3.2.3.4 Connecting to Mains and Compressor Terminals		16
		3.2.3.5	Relay Terminals	17
		3.2.3.6	Control Terminals	18
	3.2.4 Setting Up RS485 Serial Communication			19
	3.2.5	EMC-compliant Electrical Installation		20

4 Commissioning	24
4.1 Programming Interfaces	24

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Operating Guide				Contents

	4.2	Local Control Panel (LCP)		24
		4.2.1 Programming via the Quick Menu		25
		4.2.2 Programming via the Main Menu		25
		4.2.3 Data Transfer from Drive to LCP		26
		4.2.4 Data Transfer from LCP to Drive		26
		4.2.5 Restoring Factory Default Settings		26
			4.2.5.1 Recommended Initialization (via Parameter 14-22 Operation Mode)	26
			4.2.5.2 Two-finger Initialization	27
	4.3	Starting Up the Drive for the First Time		27
5	Troubleshooting			28
	5.1	Acoustic Noise or Vibration		28
	5.2	Warnings and Alarms		28
6	Specifications			32
	6.1	Electrical Data		32
		6.1.1 Electrical Data 3x200–240 V AC		32
		6.1.2 Electrical Data 3x380–480 V AC		32
	6.2	Mains Supply (L1, L2, L3)		33
	6.3	Compressor Output (U, V, W)		33
	6.4	Control Input/Output		34
		6.4.1 10 V DC Output		34
		6.4.2 24 V DC Output		34
		6.4.3	Analog Inputs	34
		6.4.4	Analog Outputs	34
		6.4.5	Digital Inputs	34
		6.4.6	Digital Outputs	35
		6.4.7 Relay Outputs, Enclosure Sizes H3–H5		35
		6.4.8 Relay Outputs, Enclosure Size H6		35
		6.4.9	RS485 Serial Communication	36
	6.5	Ambient Conditions		36
	6.6	Conforming Standards		37
	6.7	Cable Lengths and Cross-sections		37
	6.8	Acoustic Noise		37
	6.9	Shipping Dimensions		38
	6.10	Accessories and Spare Parts		38
7	Appendix			39
	7.1	Abbreviations		39

4 \| Danfoss A/S © 2021.06				AQ321748767627en-000301/130R0570

VLT® Compressor Drive CDS 803
Operating Guide	Contents

7.2 Conventions	40

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VLT® Compressor Drive CDS 803

Operating Guide	Introduction

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 qualified personnel.

Read and follow the instructions to use the drive safely and professionally.

Pay particular attention to the safety instructions and general warnings. Always keep this Operating Guide with the drive. VLT® is a registered trademark for Danfoss A/S.

1.2 Additional Resources

1.2.1 Supplementary Documentation

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

•The Programming Guide provides information on how to program and includes complete parameter descriptions.

•The Design Guide provides detailed information about capabilities and functionality to design motor control systems.

•The Modbus RTU Operating Instructions explains how to physically establish and configure communication between the Danfoss FC Series and a controller using the Modbus RTU protocol. Download the Operating Instructions from www.danfoss.com in the section Service and Support/Documentation.

See www.danfoss.com for supplementary documentation.

1.2.2 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 office for the latest drive updates (in the form of *.upd files), or download the drive updates from the Service and Support download page on www.danfoss.com.

1.3 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

AQ321748767627, version 0301	Various editorial updates.	6.0–10 kW (8–15 hp): Version 2.0
		18–30 kW (25–40 hp): Version 61.20

1.4 Approvals and Certifications

Description	Conformity mark

EU/EC Declaration of Conformity (EC/CE - European Conformity/Conformité Européenne)

Low Voltage Directive/Electromagnetic compatibility (EMC)/Restriction of Hazardous Substances (RoHS)

Countries of use: Europe

ACMA Declaration of Conformity (RCM - Regulatory Compliance Mark)

Australian Communications Media Authority (ACMA)

Low Voltage Directive/Electromagnetic compatibility (EMC)

Countries of use: Australia and New Zealand

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VLT® Compressor Drive CDS 803
Operating Guide	Introduction


Description	Conformity mark

VIT-SEPRO Declaration of Conformity (VIT - All-Union Institute of Transformer Engineering)

Low Voltage Directive/Electromagnetic compatibility (EMC)

Country of use: Ukraine

089

Moroccan Declaration of Conformity (CMIM - Moroccan Conformity Mark)

Low Voltage Directive/Electromagnetic compatibility (EMC)

Country of use: Morocco

Eurasian Economic Union Declaration of Conformity (EAC - Eurasian Conformity Mark) Customs Union Technical Regulations (CU TR)

Low voltage Directive/Electromagnetic compatibility (EMC)/Restriction of Hazardous Substances Directive (RoHS)

Countries of use: Eurasian Economic Union (Russia, Belarus, Kazakhstan, Armenia, and Kirghizstan)

Certification of Compliance UL listed (UL - Underwriters Laboratories)

Safety organization

Countries of use: USA and Canada

Certification of Compliance UL recognized (UL - Underwriters Laboratories)

Safety organization

Countries of use: USA and Canada

N O T I C E

The VLT® Compressor Drive CDS 803 with SXXX in the type code is certified against UL 508C. Example: CDS803P7K5T4E20H4XXCXXXSXXXXAXBXCXXXXDX

The VLT® Compressor Drive CDS 803 with S096 in the type code is certified against UL/EN/IEC 60730-1. Example: CDS803P30KT4E20H2XXXXXXS096XAXBXCXXXXDX

1.5 Disposal

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

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

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VLT® Compressor Drive CDS 803

Operating Guide	Introduction

1.6 CE Declaration

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VLT® Compressor Drive CDS 803

Operating Guide	Introduction

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VLT® Compressor Drive CDS 803

Operating Guide	Safety

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 Qualified Personnel

To allow trouble-free and safe operation of the unit, only qualified personnel with proven skills are allowed to transport, store, assemble, install, program, commission, maintain, and decommission this equipment.

Persons with proven skills:

•Are qualified electrical engineers, or persons who have received training from qualified electrical engineers and are suitably experienced 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 specific application.

2.3 Safety Precautions

W A R N I N G

HAZARDOUS VOLTAGE

AC drives contain hazardous voltage when connected to the AC mains or connected on the DC terminals. Failure to perform installation, start-up, and maintenance by skilled personnel can result in death or serious injury.

-Only skilled 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 fieldbus command, an input reference signal from the local control panel (LCP), via remote operation using MCT 10 software, or after a cleared fault condition.

-Disconnect the drive from the mains.

-Press [Off/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.

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VLT® Compressor Drive CDS 803

Operating Guide	Safety

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 off.

Failure to wait the specified 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 specified in the table Discharge time and is also visible on the nameplate on the 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 that the minimum size of the ground conductor complies with the local safety regulations for high touch current equipment.

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 qualified 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.

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VLT® Compressor Drive CDS 803

Operating Guide	Installation

3 Installation

3.1 Mechanical Installation

3.1.1 Side-by-side Installation

The drive can be mounted side by side but requires the clearance specified in Table 3 above and below for cooling.

Table 3: 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.

3.1.2 Operating Environment

3.1.2.1 Derating for Ambient Temperature and Switching Frequency

Ensure that the ambient temperature measured over 24 hours is at least 5 °C (9 °F) lower than the maximum ambient temperature that is specified for the drive. If the drive is operated at a high ambient temperature, decrease the constant output current. For derating specifications, see the VLT® Compressor Drive CDS 803 Design Guide listed in 1.2 Additional Resources.

3.1.2.2 Derating for Low Air Pressure and High Altitudes

The cooling capability of air is decreased at low air pressure. For altitudes above 2000 m (6562 ft), contact Danfoss regarding PELV. Below 1000 m (3281 ft) altitude, derating is not necessary. For altitudes above 1000 m (3281 ft), decrease the ambient temperature or the maximum output current. Decrease the output by 1% per 100 m (328 ft) altitude above 1000 m (3281 ft) or reduce the maximum ambient cooling air temperature by 1 °C (1.8 °F) per 200 m (656 ft).

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.

3.2.1.1 Fastener Torque Ratings

Table 4: Tightening Torques for Enclosure Sizes H3–H6, 3x200–240 V & 3x380–480 V

Power [kW (hp)]				Torque [Nm (in-lb)]

Enclo-	IP protec-	3x200–240 V	3x380–480 V	Mains	Motor	DC connec-	Control ter-	Ground	Relay
sure size	tion rat-					tion	minals
	ing

H3	IP20	–	6.0–7.5 (8.0–10)	0.8 (7)	0.8 (7)	0.8 (7)	0.5 (4)	0.8 (7)	0.5 (4)

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Operating Guide								Installation


Power [kW (hp)]				Torque [Nm (in-lb)]

H4	IP20	6.0–7.5 (8.0–	10–15 (15–20)	1.2 (11)	1.2 (11)	1.2 (11)	0.5 (4)	0.8 (7)	0.5 (4)
		10)

H5	IP20	10 (15)	18.5–22 (25–30)	1.2 (11)	1.2 (11)	1.2 (11)	0.5 (4)	0.8 (7)	0.5 (4)

H6	IP20	–	30 (40)	4.5 (40)	4.5 (40)	–	0.5 (4)	3 (27)	0.5 (4)

3.2.2 Fuses and Circuit Breakers

Fuses and circuit breakers ensure that possible damage to the drive is limited to damage inside the unit. Danfoss recommends fuses on the supply side as protection. For further information, see the application note Fuses and Circuit Breakers found on www.danfoss.com under Service and support/Documentation/Manuals & guides.

N O T I C E

Use of fuses on the supply side is mandatory for IEC 60364 (CE) and NEC 2009 (UL) compliant installations.

3.2.2.1 Recommendation of Fuses and Circuit Breakers

Table 5: Fuses and Circuit Breakers

		Circuit breakers(1)			Fuse
		UL	Non-UL		UL				Non-UL

					Bussmann	Bussmann	Bussmann	Bussmann	Maximum fuse

Power [kW (hp)]					Type RK5	Type RK1	Type J	Type T	Type gG

3x200–240 V

6.0	(8.0)				FRS-R-50	KTN-R50	JKS-50	JJN-50	gG-50
		–		–
7.5 (10)		–		–	FRS-R-50	KTN-R50	JKS-50	JJN-50	gG-50

10	(15)				FRS-R-80	KTN-R80	JKS-80	JJN-80	gG-63

3x380–480 V

6.0	(8.0)				FRS-R-25	KTS-R25	JKS-25	JJS-25	gG-25

7.5 (10)					FRS-R-25	KTS-R25	JKS-25	JJS-25	gG-25

10	(15)	–		–	FRS-R-50	KTS-R50	JKS-50	JJS-50	gG-50

18.5 (25)								JJS-80	gG-63
18.5 (25)								JJS-80	gG-63
					–	–	–
22	(30)				–	–	–	JJS-80	gG-63

30	(40)							JJS-125	gG-80

1 Circuit breakers have not been evaluated by Danfoss as part of the certification process.

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VLT® Compressor Drive CDS 803

Operating Guide	Installation

3.2.3 Electrical Wiring

3.2.3.1 Wiring Schematic

		L1
	3-phase	L2
	3-phase	L3
	power	L3
	power
	input

+10 V DC	50	(+10 V OUT)
+10 V DC
0-10 V DC-	53	(A IN)
0/4-20 mA	53	(A IN)
0/4-20 mA
0-10 V DC-	54 (A IN)
0/4-20 mA
	55 (COM A IN/OUT)
	42	0/4-20 mA A OUT / D OUT
	45	0/4-20 mA A OUT / D OUT
				Bus ter.
	12	(+24 V OUT)		<![if ! IE]> <![endif]>2 1	<![if ! IE]> <![endif]>ON
	18	(D IN)		<![if ! IE]> <![endif]>2 1	<![if ! IE]> <![endif]>ON
	18	(D IN)
			24 V (NPN)
	19	(D IN)	O V (PNP)
	19	(D IN)	24 V (NPN)
			24 V (NPN)
	20	(COM D IN)	O V (PNP)
	27	(D IN)		Bus ter.
	27	(D IN)
			24 V (NPN)	RS485
	29	(D IN)	O V (PNP)	Interface
			24 V (NPN)
			O V (PNP)