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

Introduction 6

1.1

Purpose of this Operating Guide 6

Additional Resources 6

1.2

Supplementary Documentation 6

1.2.1

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

Safety 10

Safety Symbols 10

2.1

Qualified Personnel 10

2.2

Contents

Safety Precautions 10

2.3

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

3.1.2.2

3.2

Electrical Installation 12

3.2.1

Electrical Installation in General 12

3.2.1.1

3.2.2

Fuses and Circuit Breakers 13

3.2.2.1

3.2.3

Electrical Wiring 14

3.2.3.1

3.2.3.2

3.2.3.3

Derating for Ambient Temperature and Switching Frequency 12

Derating for Low Air Pressure and High Altitudes 12

Fastener Torque Ratings 12

Recommendation of Fuses and Circuit Breakers 13

Wiring Schematic 14

Terminal Overview of Enclosure Sizes H3–H5 15

Terminal Overview of Enclosure Size H6 16

3.2.3.4

3.2.3.5

3.2.3.6

3.2.4

Setting Up RS485 Serial Communication 19

3.2.5

EMC-compliant Electrical Installation 20

Commissioning 24

4.1

Programming Interfaces 24

Connecting to Mains and Compressor Terminals 16

Relay Terminals 17

Control Terminals 18

VLT® Compressor Drive CDS 803

Operating Guide

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

4.2.5.2

4.3

Starting Up the Drive for the First Time 27

Troubleshooting 28

5.1

Acoustic Noise or Vibration 28

5.2

Warnings and Alarms 28

Specifications 32

Recommended Initialization (via Parameter 14-22 Operation Mode) 26

Two-finger Initialization 27

Contents

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

Appendix 39

7.1

Abbreviations 39

VLT® Compressor Drive CDS 803

Operating Guide

7.2 Conventions 40

Contents

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

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

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

1.4 Approvals and Certifications

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 Direc-

tive (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

Do not dispose of equipment containing electrical components together with domestic waste. Collect it separately in accordance with local and currently valid legislation.

VLT® Compressor Drive CDS 803

Operating Guide

Introduction

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

VLT® Compressor Drive CDS 803

Operating Guide

1.6 CE Declaration

Introduction

VLT® Compressor Drive CDS 803

Operating Guide

Introduction

VLT® Compressor Drive CDS 803

Operating Guide

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).

Safety

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.

Voltage [V]

Power range [kW (hp)]

Minimum waiting time (minutes)

3x200

6.0–10 (8.0–15)

3x400

6.0–7.5 (8.0–10)

3x400

10–30 (15–40)

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

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.

Power [kW (hp)]

Clearance above/below [mm (in)]

Size

IP protection rating

3x200–240 V

3x380–480 V

IP20–6.0–7.5 (8.0–10)

100 (4)

IP20

6.0–7.5 (8.0–10)

10 (15)

100 (4)

IP20

10 (15)

18.5–22 (25–30)

100 (4)

IP20–30(40)

200 (7.9)

Power [kW (hp)]

Torque [Nm (in-lb)]

Enclosure size

IP protection rating

3x200–240 V

3x380–480 V

Mains

Motor

DC connection

Control terminals

Ground

Relay

IP20–6.0–7.5 (8.0–10)

0.8 (7)

0.5 (4)

0.8 (7)

0.5 (4)

VLT® Compressor Drive CDS 803

Operating Guide

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

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

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)]

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)

IP20–30 (40)

4.5 (40)

–

0.5 (4)

3 (27)

0.5 (4)

Circuit breakers

(1)

Fuse

Non-ULULNon-UL

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

22 (30)

JJS-80

gG-63

30 (40)

JJS-125

gG-80

VLT® Compressor Drive CDS 803

Operating Guide

Installation

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.dan-

foss.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 have not been evaluated by Danfoss as part of the certification process.

L1 L2 L3

3-phase power input

+10 V DC

0-10 V DC-

50 (+10 V OUT)

54 (A IN)

53 (A IN)

55 (COM A IN/OUT)

0/4-20 mA

42 0/4-20 mA A OUT / D OUT

45 0/4-20 mA A OUT / D OUT

18 (D IN)

19 (D IN)

27 (D IN)

29 (

D IN)

12 (+24 V OUT)

24 V (NPN)

20 (COM D IN)

O V (PNP)

24 V (NPN) O V (PNP)

Bus ter.

RS485 Interface

RS485

(N RS485) 69

(P RS485) 68

(Com RS485 ) 61

(PNP)-Source (NPN)-Sink

ON=Terminated

OFF=Unterminated

1 2

240 V AC 3 A

Not present on all power sizes

Do not connect shield to 61

relay 1

relay 2

UDC+

UDC-

Motor

U V

e30bj246.10

240 V AC 3 A

VLT® Compressor Drive CDS 803

Operating Guide

3.2.3 Electrical Wiring

3.2.3.1 Wiring Schematic

Installation

Illustration 1: Basic Wiring Schematic Drawing

There is no access to UDC- and UDC+ on the following units:

IP20, 380–480 V, 30 kW (40 hp).

N O T I C E

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