Danfoss VLT CDS 303, VLT CDS 302 Operating Instructions Manual

MAKING MODERN LIVING POSSIBLE

Operating Instructions

VLT® Compressor Drives CDS 302/CDS 303

www.DanfossDrives.com

Contents Operating Instructions

Contents

1 Introduction

1.1 Introduction

1.1.1 Sequence of Operation 5

2 Safety Instructions and General Warnings

2.1 Safety and Warnings

2.1.1 High Voltage Warning 6

2.1.2 Caution 6

2.1.3 Disposal 6

2.1.4 Software Version 6

2.1.5 Safety Instructions 6

2.1.6 General Warning 7

2.1.7 Leakage Current 7

2.1.8 Residual Current Device 7

2.1.9 IT Mains 7

2.1.10 Avoid Unintended Start 7

2.2 Safe Torque O

2.2.1 Terminal 37 Safe Torque O Function 8

2.2.2 Safe Torque O Commissioning Test 13

3 How to Install

3.1 Environment

3.1.1 Ambient Temperature and Altitude 14

3.1.2 Environmental Requirements for Mechanical Installation 14

3.2 Mechanical Installation

3.2.1 Accessory Bags 14

3.2.2 Mechanical Mounting 15

3.2.3 Mechanical Dimensions 16

3.3 Electrical Installation

3.3.1 Cables General 17

3.3.2 Removal of Knockouts for Extra Cables 17

3.3.3 Mains Connection for B1, B2 and B3 18

3.3.4 Mains connection for B4, C1 and C3 18

3.3.5 Motor Compressor Connection 20

3.3.6 Motor Compressors Cables 20

3.3.7 Electrical Installation of Motor Compressor Cables 21

3.3.8 Compressor Motor Protection 21

3.3.9 Access to Control Terminals 21

Contents

VLT® Compressor Drives CDS 302/CDS 303

3.3.10 Basic Wiring Example 22

3.3.11 Electrical Installation, Control Cables 24

3.3.12 Electrical Installation - EMC Protection 26

3.3.13 Safety Ground Connection 28

3.3.14 Basic Examples of Control Connections 28

3.3.15 High-voltage Test 29

3.4 Fuses and Circuit Breakers

3.4.1 Fuses 29

3.4.2 Recommendations 29

3.4.3 CE Compliance 30

3.4.4 Fuse Specications 30

3.5 Application Example

3.5.1 BASIC Cascade/Pack Controller 34

3.5.2 System Status and Operation 35

3.5.3 Pack Compressor Wiring Diagram 35

4 Quick Set-up

4.1 Quick Set-up

4.1.1 Basic Programming Procedures 37

4.1.2 Open Loop with External Reference 37

4.1.3 PID Closed Loop with 4-20 mA Pressure Transmitter 37

4.1.4 Other Compressor Features 39

5 How to Program

5.1 How to Program on the Graphical LCP

5.1.1 Control Panel 40

5.1.2 Display Lines 40

5.1.3 Display Contrast Adjustment 40

5.1.4 Indicator Lights 41

5.2 LCP Keys

5.2.1 Function Keys 41

5.2.2 Navigation Keys 41

5.2.3 Local Control Keys 41

5.2.4 Quick Transfer of Parameter Settings 42

5.2.5 Data Storage in LCP 42

5.2.6 Initialization to Default Settings 42

5.2.7 Data Transfer from LCP to Frequency Converter 43

5.2.8 Parameter Selection 44

5.2.9 Changing Data 45

Contents Operating Instructions

5.2.10 Changing a Text Value 45

5.2.11 Changing a Group of Numeric Data Values 45

6 Parameter Descriptions

6.1 LCP Display

6.1.1 LCP Programming 46

6.2 Par. Group 0 - Operation and Display

6.3 Par. Group 1 - Load and Motor

6.4 Par. Group 3 - Reference/Ramps

6.5 Parameters: 4-** Limits/Warnings

6.6 Par. Group 5 - Digital In/Out

6.7 Par. Group 6 - Analog In/Out

6.8 Par. Group 7 - Controllers

6.9 Parameters: 8-** Communications and Options

6.10 Par. Group 13 - Smart Logic Control

6.11 Par. Group 14 - Special Functions

6.12 Par. Group 15 - Drive Information

6.13 Parameters: 16-** Data Readouts

6.14 Par. Group 25 - Cascade Controller

6.15 Par. Group 28 - Compressor Functions

102

105

106

112

122

6.16 Parameter Lists

6.16.1 Conversion 127

7 Troubleshooting

7.1 Status Messages

7.1.1 Warnings/Alarm Messages 147

8 General Specications

8.1.1 Mains Supply 3x200-240 V AC 161

8.1.2 Mains Supply 3x380-480 V AC 162

8.1.3 Mains Supply 3x525-600 V AC 163

Index

127

147

161

168

130BC396.13

Unit controller

Start/stop

High pressure cutout

Reference

Pressure sensor 4-20 mA

Oil solenoid

Drive

Low Pressure Cutout

VFD

Introduction

VLT® Compressor Drives CDS 302/CDS 303

1 Introduction

1.1 Introduction

Figure 1.1 Compressor Drive System

The VLT

Compressor Drives utilize and combine Danfoss design and manufacturing expertise. Our extensive application knowledge of refrigeration, air conditioning, and motion controls ensures an optimized product design and package solution:

A “plug & play” solution

•

Operational eciency

•

Flexibility & best control accuracy

•

Innovative and reliable solution

•

The frequency converter is 100% preset for speed open loop conguration with 0-10 V reference corresponding to

1800-5400 RPM for CDS 302 and 1500-6000 RPM for CDS

303.

Introduction Operating Instructions

1 1

The dedicated frequency converter functionality includes:

Start Up

•

Once the frequency converter has a start command, the compressor runs up to 3000 RPM and remains at that speed for 10 s. Once this initial time is complete, the frequency converter slowly ramps to the reference speed.

Shut Down

•

The stop command bypasses the normal ramp time and the frequency converter ramps the compressor to stop fast.

Short Cycle Prevention

•

The frequency converter has a minimum running time of 12 s, with an interval between starts of 5 minutes (300 s). The short cycle delay values are adjustable in parameter group 28-0* Short Cycle Protection.

Oil Injection

•

The frequency converter cycles a solenoid valve via its relay 1. This cycling ensures that the oil is distributed to the scroll set, improves tightness, and reduces internal gas leakage during the compression process.

Oil Management

•

If compressor speed is below 3000 RPM for a determined amount of time (within 60 minutes), the boost cycle runs the compressor back to 4200 RPM for a determined amount of time (within 90 s). The maximum time between xed boosts is limited to a determined amount of time (within 24 hours).

Discharge Temperature Limit

•

If the discharge temperature exceeds the warning level of 266 °F, the compressor drops in speed by 10 Hz for the next 3 minutes. The compressor continues to drop 10 Hz for each 3 minutes for as long as the temperature is over the warning level. If the discharge temperature exceeds the emergency level of 293 °C, the compressor is stops.

Crankcase Heater

•

On VSH088 and VSH117, when the compressor is stopped, the frequency converter provides a DC current to the compressor motor. The DC current keeps the oil warm and an external crankcase heater is not needed. VSH170 needs an external crankcase heater (surface sump heater or belt type).

Low Pressure Switch

•

An LP switch is mandatory with the frequency converter compressor in any type of application.

High Pressure Switch

•

The high-pressure switch must be connected to input terminal 37 of the frequency converter in series with the other safety devices.

1.1.1 Sequence of Operation

All compressor types have strong demands of speed limits to ensure the oil lubrication of the bearings. Therefore, fast acceleration from standstill to minimum speed with a special start ramp is important, when a start command is given. This is also the reason why the Compressor Drive trips with an alarm [A49] Speed Limit, if the speed falls below minimum speed e.g. when the current limit controller reduces the speed due to a high load. This alarm is reset automatically after 30 s and the compressor restarts.

If a rotor is blocked, the Compressor Drive trips with an alarm [A18] Start failed, if the speed fails to get above the minimum speed limit for the compressor within 2 s. This alarm is reset automatically after 30 s and the compressor restarts.

The manufacturer sets up the necessary start settings, motor data and all the other preferred settings for each compressor type/size. Automatically set up the values by selecting the actual compressor in 1-13 Compressor Selection.

Safety Instructions and Gen...

VLT® Compressor Drives CDS 302/CDS 303

2 Safety Instructions and General Warnings

2.1 Safety and Warnings

2.1.1 High Voltage Warning

WARNING

The voltage of the frequency converter is dangerous whenever the converter is connected to mains. Incorrect tting of the motor or frequency converter may damage the equipment, or cause serious injury, or death. It is essential to comply with the instructions in this manual as well as local and national rules and safety regulations.

WARNING

Installation in high altitudes: By altitudes above 2 km (6561 ft), contact Danfoss regarding PELV.

2.1.2 Caution

Drive

Do not dispose of equipment containing electrical components together with domestic waste. It must be collected separately with Electrical and Electronic Waste according to local and national legislation.

Compressors

Do not to throw away a used compressor, but dispose of it and its oil at a specialized recycling company site.

NOTICE!

Imposed limitations on the output frequency (due to export control regulations):

From software versions 2.4x (CDS 302) and 1.0x (CDS

303), the output frequency of the frequency converter is limited to 590 Hz.

2.1.4 Software Version

CDS 302 Operating Instructions Software version: 2.4x

CAUTION

The VLT® Compressor Drives DC link capacitors remain charged after power has been disconnected. To avoid an electrical shock hazard, disconnect the frequency converter from the mains before carrying out maintenance. Wait at least as follows before doing service on the frequency converter: CDS 302 and CDS 303: 11-22 kW 15 minutes High voltage can be present on the DC link even when the LEDs are turned o.

2.1.3 Disposal

Figure 2.1

These Operating Instructions can be used for all CDS 302 Compressor Drives® with software version 2.4x. The software version number can be read in parameter 15-43 Software Version.

CDS 303 Operating Instructions Software version: 1.0x

These Operating Instructions can be used for all CDS 303 Compressor Drives® with software version 1.0x. The software version number can be read in parameter 15-43 Software Version.

2.1.5 Safety Instructions

Make sure that the frequency converter is

•

properly connected to ground

Do not remove mains plugs or motor plugs while

•

the frequency converter is connected to mains

Protect personnel against supply voltage

•

Protect the motor against overloading according

•

to local and national regulations

Motor overload protection is included in the

•

default settings

Safety Instructions and Gen... Operating Instructions

The ground leakage current exceeds 3.5 mA

•

The [O] key is not a safety switch. It does not

•

disconnect the frequency converter from mains

2.1.6 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 VLT® Compressor Drives: Wait at least 15 minutes. Shorter time is allowed only if indicated on the nameplate for the specic unit.

2.1.7 Leakage Current

CAUTION

The ground leakage current from the frequency converter exceeds 3.5 mA. Ensure good mechanical ground connection (terminal 95) to the ground cable. Use at least 10 mm2 cable cross section or 2 times rated ground wires terminated separately.

2.1.8 Residual Current Device

CAUTION

This product can cause a DC current in the protective conductor. Where a ground fault interrupter (GFI) is used for extra protection, only use an GFI of Type B (time delayed) on the supply side of this product. See also RCD Application Note, MN90G. Protective grounding of the frequency converter and the use of RCDs must always follow local and national regulations.

2.1.9 IT Mains

CAUTION

Do not connect 400 V frequency converters with RFI- lters to mains supplies with a voltage between phase and ground of more than 440 V. For IT mains and delta ground (grounded leg), mains voltage may exceed 440 V between phase and ground. To disconnect the internal RFI capacitors from the RFI lter to ground, use 14-50 RFI 1 on the frequency converter. This procedure reduces the RFI performance to A2 level.

2.1.10 Avoid Unintended Start

While the frequency converter is connected to mains, the motor can be started/stopped using:

digital commands

•

bus commands

•

references

•

via the Local Control Panel (LCP)

•

Disconnect the frequency converter from mains whenever personal safety considerations make it necessary to avoid unintended start. To avoid unintended start, always press [OFF] before changing parameters. An electronic fault, temporary overload, a fault in the mains supply, or lost motor connection may cause a stopped motor to start. A frequency converter with Safe Torque O provides a certain degree of protection against such unintended start, if the Safe Torque O Terminal 37 is on low voltage level or disconnected.

2.2 Safe Torque O

The frequency converter can perform the safety function

Safe Torque Stop Category 0 (as dened in EN 60204-12).

Before integration and use of Safe Torque O in an installation, perform a thorough risk analysis to determine whether the Safe Torque O functionality and safety levels are appropriate and sucient. Safe Torque O is designed and approved suitable for the requirements of:

•

Refer to EN IEC 61800-5-2 for details of Safe torque o

(STO) function.

Refer to EN IEC 60204-1 for details of stop category 0

and 1.

Activation and Termination of Safe Torque

The Safe Torque O (STO) function is activated by removing the voltage at terminal 37 of the safe inverter. By connecting the safe inverter to external safety devices providing a safe delay, an installation for a Safe Torque O Category 1 can be obtained. The Safe Torque O function can be used for asynchronous, synchronous, and permanent magnet motors.

O (STO, as dened by EN IEC 61800-5-21) and

Safety Category 3 in EN 954-1 (and EN ISO 13849-1)

Performance Level "d" in EN ISO 13849-1:2008

SIL 2 Capability in IEC 61508 and EN 61800-5-2

SILCL 2 in EN 62061

O

2 2

Safety Instructions and Gen...

VLT® Compressor Drives CDS 302/CDS 303

WARNING

After installation of Safe Torque O (STO), a commissioning test as specied in section Safe Torque O Commissioning Test in the Design Guide must be performed. A passed commissioning test is mandatory after rst installation and after each change to the safety installation.

Safe Torque O Technical Data

The following values are associated to the dierent types of safety levels:

Reaction time for T37

Maximum reaction time: 10 ms

•

Reaction time = delay between de-energizing the STO input and switching o the frequency converter output bridge.

Data for EN ISO 13849-1

Performance Level "d"

•

MTTFd (Mean Time To Dangerous Failure): 24816

•

years

DC (Diagnostic Coverage): 99%

•

Category 3

•

Lifetime 20 years

•

Data for EN IEC 62061, EN IEC 61508, EN IEC 61800-5-2

SIL 2 Capability, SILCL 2

•

PFH (Probability of Dangerous failure per

•

Hour)=7e-10FIT=7e-19/h

SFF (Safe Failure Fraction) >99%

•

HFT (Hardware Fault Tolerance)=0 (1001

•

architecture)

Lifetime 20 years

•

Data for EN IEC 61508 low demand

PFDavg for one-year proof test: 3, 07E-14

•

PFDavg for three year proof tests: 9, 20E-14

•

PFDavg for

•

No maintenance of the STO functionality is needed.

Take the necessary security measures, e.g. installation in a closed cabinet that is only accessible for skilled personnel.

SISTEMA Data

Functional safety data is available via a data library for use with the SISTEMA calculation tool from the IFA (Institute for Occupational Safety and Health of the German Social Accident Insurance), and data for manual calculation. The library is permanently completed and extended.

ve year proof tests: 1, 53E-13

Abbrev. Ref. Description

Cat. EN 954-1 Category, level “B, 1-4” FIT Failure In Time: 1E-9 hours HFT IEC 61508 Hardware Fault Tolerance: HFT = n

means, that n+1 faults could cause a loss of the safety function

MTTFd EN ISO

13849-1

PFH IEC 61508 Probability of Dangerous Failures per

PL EN ISO

13849-1

SFF IEC 61508 Safe Failure Fraction [%]; Percentage part

SIL IEC 61508 Safety Integrity Level STO EN

61800-5-2

SS1 EN 61800

-5-2

Table 2.1 Abbreviations Related to Functional Safety

The PFD Failure probability in the event of a request of the safety function.

value (Probability of Failure on Demand)

avg

Mean Time To Failure - dangerous. Unit: years

Hour. Consider the PFH value when the safety device is operated in high demand (more often than once per year); or operated in continuous mode, where the frequency of demands for operation made on a safety-related system is greater than one per year. Discrete level used to specify the ability of safety-related parts of control systems to perform a safety function under foreseeable conditions. Levels a-e.

of safe failures and dangerous detected failures of a safety function or a subsystem related to all failures.

Safe Torque O

Safe Torque O 1

2.2.1 Terminal 37 Safe Torque O Function

The frequency converter is available with Safe Torque O functionality via control terminal 37. Safe Torque O disables the control voltage of the power semiconductors of the frequency converter output stage. This in turn prevents generating the voltage required to rotate the motor. When the Safe Torque O (T37) is activated, the frequency converter issues an alarm, trips the unit, and coasts the motor to a stop. Manual restart is required. The Safe Torque O function can be used as an emergency stop for the frequency converter. In normal operating mode when Safe Torque O is not required, use the regular stop function instead. When automatic restart is used, ensure the requirements of ISO 12100-2 paragraph

5.3.2.5 are fullled.

Safety Instructions and Gen... Operating Instructions

Liability Conditions

Ensure that qualied personnel installs and operates the Safe Torque O function:

Read and understand the safety regulations

•

concerning health and safety/accident prevention

Understand the generic and safety guidelines

•

given in this description and the extended description in the relevant Design Guide

Have a good knowledge of the generic and safety

•

standards applicable to the specic application

User is dened as:

integrator

•

operator

•

service technician

•

maintenance technician

•

Standards

Use of Safe Torque all provisions for safety, including relevant laws, regulations and guidelines. The optional Safe Torque O function complies with the following standards.

IEC 60204-1: 2005 category 0 – uncontrolled stop

•

IEC 61508: 1998 SIL2

•

IEC 61800-5-2: 2007 – safe torque

•

function

IEC 62061: 2005 SIL CL2

•

ISO 13849-1: 2006 Category 3 PL d

•

ISO 14118: 2000 (EN 1037) – prevention of

•

unexpected startup

The information and instructions of the instruction manual are not sucient for a proper and safe use of the Safe Torque O functionality. The related information and instructions of the relevant Design Guide must be followed.

Protective Measures

Qualied and skilled personnel are required for

•

installation and commissioning of safety engineering systems

The unit must be installed in an IP54 cabinet or

•

in an equivalent environment. In special applications, a higher IP degree is required

The cable between terminal 37 and the external

•

safety device must be short circuit protected according to ISO 13849-2 table D.4

When external forces inuence the motor axis (for

•

example, suspended loads), more measures are

O on terminal 37 requires fullling of

o (STO)

required (for example, a safety holding brake) to eliminate potential hazards

Safe Torque O Installation and Set-Up

WARNING

SAFE TORQUE OFF FUNCTION!

The Safe Torque O function does NOT isolate mains voltage to the frequency converter or auxiliary circuits. Perform work on electrical parts of the frequency converter or the motor only after isolating the mains voltage supply and waiting the length of time specied in chapter 2.1 Safety and Warnings. Failure to isolate the mains voltage supply from the unit and waiting the time specied could result in death or serious injury.

It is not recommended to stop the frequency

•

converter by using the Safe Torque O function. If a running frequency converter is stopped by using the function, the unit trips and stops by coasting. If unacceptable or dangerous, use another stop mode to stop the frequency converter and machinery, before using this function. Depending on the application, a mechanical brake can be required.

For synchronous and permanent magnet motor

•

frequency converters, in a multiple IGBT power semiconductor failure: In spite of the activation of the Safe Torque produce an alignment torque which maximally rotates the motor shaft by 180/p degrees. p denotes the pole pair number.

This function is suitable for performing

•

mechanical work on the system or aected area of a machine only. It does not provide electrical safety. Do not use this function as a control for starting and/or stopping the frequency converter.

To perform a safe installation of the frequency converter, follow these steps:

1. Remove the jumper wire between control terminals 37 and 12 or 13. Cutting or breaking the jumper is not sucient to avoid shortcircuiting. (See jumper on Figure 2.2.)

2. Connect an external Safety monitoring relay via a NO safety function to terminal 37 (Safe Torque O) and either terminal 12 or 13 (24 V DC). Follow the instruction for the safety device. The Safety monitoring relay must comply with Category 3 /PL “d” (ISO 13849-1) or SIL 2 (EN

62061).

O function, the system can

2 2

12/13

130BA874.10

130BC971.10

Safety Instructions and Gen...

VLT® Compressor Drives CDS 302/CDS 303

O. Moreover, perform the test after each modication of the installation.

Example with STO

A safety relay evaluates the E-Stop button signals and triggers an STO function on the frequency converter in the event of an activation of the E-Stop button (See Figure 2.4). This safety function corresponds to a category 0 stop (uncontrolled stop) in accordance with IEC 60204-1. If the function is triggered during operation, the motor runs down in an uncontrolled manner. The power to the motor is safely removed, so that no further movement is possible. It is not necessary to monitor plant at a standstill. If an external force eect can occur, provide additional measures to prevent any potential movement (for example mechanical brakes).

NOTICE!

Figure 2.2 Jumper between Terminal 12/13 (24 V) and 37

For all applications with Safe Torque O it is important that short circuit in the wiring to T37 can be excluded. Exclude the short circuit as described in EN ISO 13849-2 D4 by the use of protected wiring (shielded or segregated).

Figure 2.3 Installation to Achieve a Stopping Category 0 (EN

60204-1) with Cat. 3 /PL “d” (ISO 13849-1) or SIL 2 (EN 62061).

1 Frequency converter 2 [Reset] key 3 Safety relay (cat. 3, PL d or SIL2 4 Emergency stop button 5 Short-circuit protected cable (if not inside installation IP54

cabinet)

Table 2.2 Legend to Figure 2.3

Safe Torque O Commissioning Test

After installation and before rst operation, perform a commissioning test of the installation using Safe Torque

Example with SS1

SS1 corresponds to a controlled stop, stop category 1 according to IEC 60204-1 (see Figure 2.5). When activating the safety function, the frequency converter performs a normal controlled stop. This can be activated through terminal 27. After the safe delay time has expired on the external safety module, the STO will be triggered and terminal 37 will be set low. Ramping down as congured in the frequency converter. If the frequency converter is not stopped after the safe delay time, the activation of STO will coast the frequency converter.

NOTICE!

When using the SS1 function, the brake ramp of the frequency converter is not monitored with respect to safety.

Example with Category 4/PL e application

Where the safety control system design requires two channels for the STO function to achieve Category 4/PL e, implement one channel via Safe Torque O T37 (STO) and the other by a contactor. Connect the contactor in either the frequency converter input or output power circuits and controlled by the Safety relay (see Figure 2.6). The contactor must be monitored through an auxiliary guided contact, and connected to the reset input of the Safety Relay.

Paralleling of Safe Torque O input the one Safety Relay

Safe Torque O inputs T37 (STO) may be connected directly if it is required to control multiple frequency converters from the same control line via one Safety Relay

130BC972.10

130BC973.10

130BC974.10

K 1

Safety Instructions and Gen... Operating Instructions

(see Figure 2.7). Connecting inputs increases the probability of a fault in the unsafe direction. A fault in one frequency converter can result in all frequency converters becoming enabled. The probability of a fault for T37 is so low, that the resulting probability still meets the requirements for SIL2.

Figure 2.4 STO Example

1 Frequency converter 2 [Reset] key 3 Safety relay 4 Emergency stop

Table 2.4 Legend to Figure 2.5

2 2

1 Frequency converter 2 [Reset] key 3 Safety relay

Figure 2.6 STO Category 4 Example

4 Emergency stop

Table 2.3 Legend to Figure 2.4

1 Frequency converter 2 [Reset] key 3 Safety relay 4 Emergency stop

Table 2.5 Legend to Figure 2.6

Figure 2.5 SS1 Example

130BC975.10

Safety Instructions and Gen...

VLT® Compressor Drives CDS 302/CDS 303

1. Activate the Safe Torque O function by

removing the 24 V DC voltage supply to the terminal 37.

2. After activation of Safe Torque O (that is, after the response time), the frequency converter coasts (stops creating a rotational eld in the motor). The response time is typically less than 10 ms.

The frequency converter is guaranteed not to restart creation of a rotational eld by an internal fault (in accordance with Cat. 3 of EN 954-1, PL d acc. EN ISO 13849-1 and SIL 2 acc. EN 62061). After activation of Safe Torque O, the display shows the text ”Safe Stop activated”. The associated help text says, "Safe Stop has been activated. This means that the Safe Torque O has been activated, or that normal operation has not been resumed yet after Safe Torque O activation”.

NOTICE!

The requirements of Cat. 3 (EN 954-1)/PL “d” (ISO 13849-1) are only fullled while 24 V DC supply to terminal 37 is kept removed or low by a safety device which itself fullls Cat. 3 (EN 954-1) PL “d” (ISO 13849-1). If external forces act on the motor, it must not operate without additional measures for fall protection. External forces can arise for example, in the event of vertical axis (suspended loads) where an unwanted movement, for example caused by gravity, could cause a hazard. Fall protection measures can be additional mechanical

Figure 2.7 Paralleling of Multiple Drives Example

1 Frequency converter 2 24 V DC 3 [Reset] key 4 Safety relay 5 Emergency stop

Table 2.6 Legend to Figure 2.7

brakes.

By default the Safe Torque O function is set to an Unintended Restart Prevention behaviour. Therefore, to resume operation after activation of Safe Torque O,

1. reapply 24 V DC voltage to terminal 37 (text Safe Torque O activated is still displayed)

2. create a reset signal (via bus, Digital I/O, or [Reset] key.

WARNING

Safe Torque O activation (that is removal of 24 V DC voltage supply to terminal 37) does not provide electrical safety. The Safe Torque O function itself is therefore not

sucient to implement the Emergency-O function as dened by EN 60204-1. Emergency-O requires measures

The Safe Torque O function can be set to an Automatic Restart behaviour. Set the value of parameter 5-19 Terminal 37 Safe Stop from default value [1] to value [3]. Automatic Restart means that Safe Torque O is terminated, and normal operation is resumed, as soon as the 24 V DC are applied to Terminal 37. No Reset signal is required.

of electrical isolation, for example, by switching o mains via an additional contactor.

Safety Instructions and Gen... Operating Instructions

WARNING

Automatic Restart Behaviour is permitted in one of the two situations:

1. The Unintended Restart Prevention is implemented by other parts of the Safe Torque O installation.

2. A presence in the dangerous zone can be physically excluded when Safe Torque O is not activated. In particular, paragraph 5.3.2.5 of ISO 12100-2 2003 must be observed

2.2.2 Safe Torque O Commissioning Test

After installation and before rst operation, perform a commissioning test of an installation or application, using Safe Torque O. Perform the test again after each modication of the installation or application involving the Safe Torque O.

NOTICE!

A passed commissioning test is mandatory after rst installation and after each change to the safety installation.

The commissioning test (select one of cases 1 or 2 as applicable):

Case 1: Restart prevention for Safe Torque O is required (that is Safe Torque O only where parameter 5-19 Terminal 37 Safe Stop is set to default value [1], or combined Safe Torque O and MCB 112 where parameter 5-19 Terminal 37 Safe Stop is set to [6] PTC 1 & Relay A or [9] PTC 1 & Relay W/A):

1.1 Remove the 24 V DC voltage supply to terminal 37 using the interrupt device while the frequency converter drives the motor (that is mains supply is not interrupted). The test step is passed when

the motor reacts with a coast, and

•

the mechanical brake is activated (if

•

connected)

the alarm “Safe Torque O [A68]” is

•

displayed in the LCP, if mounted

1.2 Send Reset signal (via Bus, Digital I/O, or [Reset] key). The test step is passed if the motor remains in the Safe Torque O state, and the mechanical brake (if connected) remains activated.

1.3 Reapply 24 V DC to terminal 37. The test step is passed if the motor remains in the coasted

state, and the mechanical brake (if connected) remains activated.

1.4 Send Reset signal (via Bus, Digital I/O, or [Reset] key). The test step is passed when the motor becomes operational again.

The commissioning test is passed if all four test steps 1.1,

1.2, 1.3 and 1.4 are passed.

Case 2: Automatic Restart of Safe Torque O is wanted and allowed (that is, Safe Torque O only where parameter 5-19 Terminal 37 Safe Stop is set to [3], or combined Safe Stop and MCB 112 where

parameter 5-19 Terminal 37 Safe Stop is set to [7] PTC 1 & Relay W or [8] PTC 1 & Relay A/W):

2.1 Remove the 24 V DC voltage supply to terminal 37 by the interrupt device while the frequency converter drives the motor (that is mains supply is not interrupted). The test step is passed when

the motor reacts with a coast, and

•

the mechanical brake is activated (if

•

connected)

the alarm “Safe Stop [A68]” is displayed

•

in the LCP, if mounted

2.2 Reapply 24 V DC to terminal 37.

If the motor becomes operational again, The test step is passed. If both test steps 2.1 and 2.2 are passed, the commissioning test is passed.

NOTICE!

See warning on the restart behaviour in

chapter 2.2.1 Terminal 37 Safe Torque O Function

WARNING

The Safe Torque O function can be used for asynchronous, synchronous and permanent magnet motors. Two faults can occur in the power semiconductor of the frequency converter. When using synchronous or permanent magnet motors a residual rotation can result from the faults. The rotation can be calculated to Angle = 360/(Number of Poles). The application using synchronous or permanent magnet motors must take this residual rotation into consideration and ensure that it does not pose a safety risk. This situation is not relevant for asynchronous motors.

2 2

130BT330.10

RELAY 1

RELAY 2

130BT346.10

WARNING:

Risk of Electric Shock - Dual supply Discunnect mains and loadsharing before service

130BT347.10

WARNING:

Risk of Electric Shock - Dual supply Disconnect mains and loadsharing before service

How to Install

3 How to Install

VLT® Compressor Drives CDS 302/CDS 303

3.1 Environment

3.1.1 Ambient Temperature and Altitude

The normal ambient temperature supported by the CDS is

Mechanical Installation

3.2

3.2.1 Accessory Bags

Find the following parts included in the accessory bag:

-14000000 °F to +122 °F without derating. The CDS operates normally down to -4 °F with only the LCP display function impaired but without performance reduction.

For ambient temperatures above +122 °F, it is mandatory to integrate the derating output factor for the maximum compressor electrical motor power/current.

For altitudes above 3280 ft (1000 m), apply derating as shown in Table 3.1.

For more details on derating due to environmental factors,

Figure 3.1 Enclosures B1 and B2, IP21/IP55/Type 1/Type 12

contact Danfoss technical support.

Altitude [ft/m] Derating factor

3280/1000 1 4921/1500 0.95 6561/2000 0.90 8202/2500 0.86 9842/3000 0.82

11482/3500 0.78

Table 3.1 Altitude Derating Factor

Figure 3.2 Enclosure B3, IP20/Chassis

3.1.2 Environmental Requirements for Mechanical Installation

The unit is air-cooled. To protect the unit from overheating, ensure that the ambient temperature does not exceed the maximum temperature stated for the 24-hour average temperature. If the ambient temperature is in the range of 113 °F to 131 °F, derating becomes relevant. If derating for ambient temperature is not taken into account, the service life of the unit is reduced.

Figure 3.3 Enclosure B4, IP20/Chassis

130BA406.10

61 68 6

39 42 50 53 54 5

03 02 01

06 05 04

C D

J K

WARNING:

Risk of Electric Shock - Dual supply Disconnect mains and loadsharing before service

ISOA0021

130BT348.10

Risk of Electric Shock - Dual supply Disconnect mains and loadsharing before service

WARNING:

RELAY 1

RELAY 2

130BA419.10

How to Install Operating Instructions

Figure 3.4 Enclosures C1 and C2, IP55/66/Type 1/Type 12

Figure 3.5 Enclosure C3, IP20/Chassis

3 3

3.2.2 Mechanical Mounting

1. Drill holes in accordance with the measurements given.

2. Provide screws suitable for the surface on which the compressor drive should be mounted.

3. Retighten all four screws.

The frequency converter IP20 allows side-by-side installation. Because of the need for cooling, there must be a minimum of 7.9 in (200 mm) free air passage above and below the frequency converter. The back wall must always be solid. All frequency converters are equipped with a back metal plate to guarantee proper heat exchanger ventilation. Never remove this metal sheet.

Figure 3.6 Clearance

Frame size

A1*/A2/A3/A4/A5

/B1

B2/B3/B4/C

1/C3

C2/C4

a [Inch/mm] 3.3/100 7.9/200 8.9/225 b [inch/mm] 3.3/100 7.9/200 8.9/225

Table 3.2 Air Passage for Dierent Frame Sizes

130BA219.11

130BA228.11

How to Install

VLT® Compressor Drives CDS 302/CDS 303

3.2.3 Mechanical Dimensions

IP 20 Chassis T2 [240 V] T4 [480 V] T6 [575 V]

VSH088 [15 kW] B4 B3 B3

VSH117 [18 kW] C3 B4 B4 VSH170 [22 kW] C3 B4 B4 IP 55 NEMA 12 VSH088 [15 kW] C1 B1 B1 VSH117 [18 kW] C1 B2 B2 VSH170 [22 kW] C1 B2 B2

Table 3.3 Related VSH Numbers

Table 3.4 Dimensional Drawings

B1 B2 B3 B4 C1 C3

Height [inch/mm]

Backplate A 18.90/480 25.59/650 15.71/399 20.47/520 26.77/680 21.65/550 Distance between mounting holes a 17.87//454 24.57/624 14.96/380 19.49/495 25.51/648 20.51/521

Width [inch/mm]

Back plate B 9.53/242 9.53/242 6.50/165 9.06/230 12.13/308 12.13/308 Distance between mounting holes b 8.28/210 8.28/210 5.51/140 7.87/200 10.71/272 10.63/270

Depth [inch/mm]

Without option C 10.24/260 10.24/260 9.80/249 9.53/242 12.21/310 13.11/333 With option C 10.24/260 10.24/260 10.24/260 9.53/242 12.21/310 13.11/333

Screw holes [inch/mm]

c 0.47/12.0 0.47/12.0 0.32 0.49/12.0 d Ø 0.75/19.0 Ø 0.75/19.0 0.47/12.0 Ø 0.75/19.0 e Ø 0.35/9 Ø 0.35/9 0.34/8.8 0.33/8.5 Ø 0.35/9 0.33/8.5 f 0.35/9 0.35/9 0.31/7.9 0.59/15 0.38/9.8 0.67/17

Other Specications

Max. weight [lbs/kg] 50.4/23 59.53/27 26.46/12 51.81/23.5 99.21/45 77.16/35

Table 3.5 Mechanical Dimensions

How to Install Operating Instructions

3.3 Electrical Installation

3.3.1 Cables General

CAUTION

Cables general: Always comply with national and local regulations on cable cross-sections.

Frame

size

B1 5.5-7.5 11-15 15

B2 11 18.5-22 18.5-22

B3 5.5-7.5 11-15 15

B4 11-15 18.5-30 18.5-22

C3 18.5-22 - -

200-240 V

[kW]

380-500 V

[kW]

525-690 V

[kW]

Cable for Tightening torque

Mains, motor cables 1.8 Relay 0.5-0.6 Ground 2-3 Mains 4.5 Motor cables 4.5 Relay 0.5-0.6 Ground 2-3 Mains, motor cables 1.8 Relay 0.5-0.6 Ground 2-3 Mains, motor cables 4.5 Relay 0.5-0.6 Ground 2-3 Mains, motor cables 10 Relay 0.5-0.6 Ground 2-3

3 3

[Nm]

Table 3.6 Tightening Torque

3.3.2 Removal of Knockouts for Extra Cables

Remove cable entry from the frequency converter (avoiding foreign parts in the frequency converter when

•

removing knockouts)

Support cable entry around the knockout that should be removed

•

The knockout can now be removed with a strong mandrel and a hammer

•

Remove burrs from the hole

•

Mount cable entry on frequency converter

•

130BT332.10

130BA720.10

How to Install

VLT® Compressor Drives CDS 302/CDS 303

3.3.3 Mains Connection for B1, B2 and B3

NOTICE!

Frequency converter sizes dier, but terminal numbers are always the same. Incoming power is always 91, 92, 93 labeled L1, L2, L3.

NOTICE!

For correct cable dimensions see chapter 8 General

Specications.

Figure 3.9 How to Connect to Mains and Grounding for B3

with RFI

Figure 3.7 How to Connect to Mains and Grounding for B1

and B2

Figure 3.8 How to Connect to Mains and Grounding for B3

without RFI

3.3.4 Mains connection for B4, C1 and C3

NOTICE!

Frequency converter sizes dier but terminal numbers are always the same. Incoming power is always 91, 92, 93 labeled L1, L2, L3.

L1 91

L2 92

L3 93

L1 91

L2 92

L3 93

U 96

V 97

W 98

DC-88

DC+89

R-81

R+82

130BA714.10

130BA389.10

91 L1

92 L2

93 L3

91 92 93

96 97 98

88 89

81 82

130BA718.10

How to Install Operating Instructions

3 3

Figure 3.10 How to Connect to Mains and Grounding for B4

Figure 3.11 How to Connect to Mains and Grounding for C1

and C2

Figure 3.12 How to Connect C3 to Mains and Grounding

130BC399.10

130BT333.10

L 1

L 2

L 3

130BT336.10

How to Install

VLT® Compressor Drives CDS 302/CDS 303

3.3.5 Motor Compressor Connection

NOTICE!

Always wire terminal 96 (U) to T1, 97 (V) to T2, and 98 (W) to T3.

Figure 3.14 How to Connect to Motor Terminals B1/B2

Figure 3.13 Motor/Compressor Wiring

Motor compressor cable must be screened/armored. If an unscreened/unarmored cable is used, some EMC requirements are out of compliance. For more information, see EMC specications.

1. Fasten decoupling plate to the bottom of the frequency converter with screws and washers from the accessory bag.

2. Attach motor compressor cable to terminals 96 (U), 97 (V), 98 (W).

3. Connect to ground connection (terminal 99) on decoupling plate with screws from the accessory bag.

4. Insert terminals 96 (U), 97 (V), 98 (W) and motor compressor cable to terminals labeled MOTOR.

5. Fasten screened cable to decoupling plate with screws and washers from the accessory bag.

6. Connect U, V, W for motor compressor clockwise.

Figure 3.15 How to Connect to Mains and Ground without

Mains Disconnect

3.3.6 Motor Compressors Cables

Correct dimensioning of motor compressor cable crosssection and length is described in the application manual.

Use a screened/armored motor compressor cable

•

to comply with EMC emission specications

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 frequency converters and to the metal cabinet of the motor compressor

Make the screen connections with the largest

•

possible surface area (cable clamp). Use the supplied installation devices in the frequency converter for making the screen connections.

130BT248.10

130BT334.10

How to Install Operating Instructions

3.3.7 Electrical Installation of Motor Compressor Cables

Screening of cables

Avoid installation with twisted screen ends (pigtails). They reduce the screening eect at higher frequencies.

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.

Aluminum conductors Aluminium conductors are not recommended. Terminals accept aluminium conductors, but clean the conductor surface and remove and seal the oxidation by neutral acidfree Vaseline 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 gas tight joint, otherwise the aluminium surface oxidizes again.

3.3.9 Access to Control Terminals

3 3

Figure 3.16 B3, B4 and C3 Enclosures

3.3.8 Compressor Motor Protection

The frequency converter fully provides electrical compressor motor protection.

The frequency converter makes through an

•

electronic current measurement anti-overload and lock-rotor compressor motor protection (see description in the application manual).

The frequency converter is protected against

•

short circuits on compressor terminals T1, T2, T3

If a mains phase is missing, the frequency

•

converter trips or issues a warning (depending on the load)

If a compressor motor phase is missing, the

•

frequency converter trips

The frequency converter is protected against

•

ground faults on compressor motor terminals T1, T2, T3

Figure 3.17 C1, B1 and B2 Enclosures

Control terminals are located beneath the LCP. The inside of the removable cover shows the terminals.

130BA012.12

130BT312.10

130BT311.10

130BA150.10

9 - 10 mm

(0.37 in)

130BT306.10

How to Install

VLT® Compressor Drives CDS 302/CDS 303

To remove the cable from the terminal:

1. Insert a screwdriver in the square hole.

Figure 3.18 Control Terminals

2. Pull out the cable.

1. 10 pole plug digital I/O

2. 3 pole plug RS-485 Bus

3. 6 pole analog I/O

4. USB Connection

To mount the cable to the terminal:

1. Strip isolation of 9-10 mm.

2. Insert a screwdriver in the square hole.

3. Insert the cable in the adjacent circular hole.

4. Remove the screwdriver. The cable is now mounted to the terminal.

Figure 3.20 Removing the Cable

Figure 3.21 Stripping the Cable

3.3.10 Basic Wiring Example

1. Mount terminals from the accessory bag to the front of the frequency converter.

Figure 3.19 Mounting the Cable

Figure 3.22 Mounting the Terminals

How to Install Operating Instructions

2. Connect terminals 18, 27 and 37 to +24 V (terminal 12/13)

Default settings: 18 = start 27 = coast inverse

3 3

Figure 3.23 Example of Basic Wiring

How to Install

VLT® Compressor Drives CDS 302/CDS 303

3.3.11 Electrical Installation, Control Cables

Use terminal 37 as input for safe stop. In rare cases, control cables more than 100 m (330 ft) and analog signals result in 50/60 Hz ground loops due to noise from mains supply cables. If this situation occurs, break the screen or insert a 100 nF

capacitor between screen and chassis. Connect the digital and analog inputs and outputs separately to the frequency converter common inputs (terminal 20, 55, 39) to avoid ground currents aecting the system.

Figure 3.24 Electrical Diagram - Control Cables

Control cables must be shielded/armored. To connect the screen to the frequency converter decoupling plate for control cables, use a clamp from the accessory bag.

130BT340.11

How to Install Operating Instructions

Figure 3.25 Control Cable Connection

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 ground via an internal RC link. To reduce the dierential mode interference between the conductors, use twisted-pair cables.

3 3

Figure 3.26 indicates how correct grounding is carried out and what to do if in doubt.

a. Correct grounding

Control cables and cables for serial communication must

tted with cable clamps at both ends to ensure the

be best possible electrical contact.

b. Wrong grounding

Do not use twisted cable ends (pigtails). They increase the screen impedance at high frequencies.

c. Protection concerning ground potential between PLC (Program Logic Controller) and frequency converter

If the ground potential between the frequency converter and the PLC (etc.) is dierent, electric noise may occur that disturbs the entire system. Solve this problem by tting an equalizing cable, next to the control cable. Minimum cable cross-section: 16 mm2.

d. For 50/60 Hz ground loops

If long control cables are used, 50/60 Hz ground loops may occur. Solve this problem by connecting one end of the screen to ground via a 100 nF capacitor (keeping leads short).

Figure 3.26 Examples of ground Wiring

How to Install

VLT® Compressor Drives CDS 302/CDS 303

3.3.12 Electrical Installation - EMC Protection

The following is a guideline to good engineering practice

when installing frequency converters. To comply with EN 61800-3 First environment, follow these guidelines. 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.

Good engineering practice to ensure EMC-correct electrical installation

Use only braided screened/armored motor

•

compressor cables and braided screened/armored control cables. The screen should provide a minimum coverage of 80%. The screen material must be metal, not limited to but typically copper, aluminum, 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 frequency converter to the motor compressor is required. The EMC performance of exible conduits varies a lot and information from the manufacturer must be obtained.

Leave the screen as close to the connectors as possible.

Figure 3.27 shows an example of an EMC-correct electrical installation of an IP20 frequency converter. The frequency converter is tted in an installation cabinet with an output contactor and connected to a PLC, which is installed in a separate cabinet. Other ways of doing the installation may have just as good an EMC performance, provided the above guide lines to engineering practice are followed. Installing without following the guideline, and using unscreened cables and control wires do not comply with all emission requirements, although the immunity requirements are

Connect the screen/armor/conduit to ground at

•

both ends for motor compressor cables as well as for control cables. In some cases, it is not possible to connect the screen in both ends. If so, connect the screen at the frequency converter. See also chapter 3.3.11 Electrical Installation, Control Cables.

Avoid terminating the screen/armor with twisted

•

ends (pigtails). It increases the high frequency impedance of the screen, which reduces its eectiveness at high frequencies. Use low impedance cable clamps or EMC cable glands instead.

Avoid using unscreened/unarmored motor

•

compressor or control cables inside cabinets housing the frequency converter(s).

fullled.

How to Install Operating Instructions

3 3

Figure 3.27 EMC Correct Installation of an IP20 Frequency Converter

130BC398.10

How to Install

VLT® Compressor Drives CDS 302/CDS 303

3.3.13 Safety Ground Connection

The frequency converter has a high leakage current and must be grounded appropriately for safety reasons according to EN

50178. The ground leakage current from the frequency converter exceeds 3.5 mA. To ensure a good mechanical connection

from the ground cable to the ground connection (terminal 95), the cable cross-section must be at least 10 mm2 or 2 rated ground wires terminated separately.

3.3.14 Basic Examples of Control Connections

Controls using an external controller with 0-10 V signal. It is not necessary to change any parameters, as this is the default value.

Figure 3.28 Example of External Controller with 0-10 V Signal

Controls using an external controller with 4-20 mA signal. Change switch 53 from U to I. It is not necessary to change any parameters, as this is the default value.

Figure 3.29 Example of External Controller with 4-20 mA Signal

+ 142 hidden pages

Danfoss VLT CDS 303, VLT CDS 302 Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual