Contents
Contents
Operating Instructions VLT® CDS302 and CDS303
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 Stop of the Frequency Converter
2.2.1 Terminal 37 Safe Stop Function 8
2.2.2 Safe Stop Commissioning Test 13
4
6
6
7
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 15
3.3 Electrical Installation
3.3.1 Cables General 17
3.3.2 Removal of Knockouts for Extra Cables 17
3.3.5 Motor Compressor Connection 20
3.3.6 Motor Compressors Cables 21
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
3.3.10 Basic Wiring Example 22
14
14
14
17
3.3.11 Electrical Installation, Control Cables 24
3.3.12 Electrical Installation - EMC Protection 26
3.3.13 Safety Earth Connection 27
3.3.14 Basic Examples of Control Connections 28
MG34M302 - VLT® is a registered Danfoss trademark/Commercial Compressor 1
Contents
Operating Instructions VLT® CDS302 and CDS303
3.3.15 High Voltage Test 29
3.4 Fuses and Circuit Breakers
3.4.2 Recommendations 29
3.4.3 CE Compliance 30
3.5 Application Example - Pack Controller
4 Quick Set-up
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
29
34
37
40
40
41
5.2.5 Data Storage in LCP 42
5.2.6 Initialisation to Default Settings 42
5.2.7 Data Transfer from LCP to Frequency Converter 43
5.2.8 Parameter Selection 43
5.2.9 Changing Data 43
5.2.10 Changing a Text Value 43
5.2.11 Changing a Group of Numeric Data Values 43
6 Parameter Descriptions
6.1 LCP Display
6.1.1 LCP Programming 45
6.2 Parameters: 0-** Operation and Display
6.3 Parameters: 1-** Load and Motor
6.4 Parameters: 3 -** Reference/Ramps
6.5 Parameters: 4-** Limits/Warnings
6.6 Parameters: 5-** Digital In/Out
6.7 Parameters: 6-** Analog In/Out
6.8 Parameters: 7-** Controllers
45
45
46
52
53
57
59
69
73
6.9 Parameters: 8-** Communications and Options
6.10 Parameters: 13-** Smart Logic Control
6.11 Parameters: 14-** Special Functions
6.12 Parameters: 15-** Drive Information
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Contents
Operating Instructions VLT® CDS302 and CDS303
6.13 Parameters: 16-** Data Read-outs
6.14 Parameters: 25-** Cascade Controller
6.15 Parameters: 28-** Compressor Functions
6.16 Parameter Lists
6.16.1 Conversion 122
7 Troubleshooting
7.1.1 Warnings/Alarm Messages 142
8 General Specifications
Index
101
107
118
122
142
153
160
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Introduction
Operating Instructions VLT® CDS302 and CDS303
11
1 Introduction
Illustration 1.1 Compressor Drive System
®
The Compressor Drive
design and manufacturing expertise. Our extensive
application knowledge of Refrigeration, Air Conditioning
and Motion Controls ensures an optimised product design
and package solution:
One package “plug & play” solution.
•
Operation efficiency.
•
Flexibility & best control accuracy.
•
Innovative and reliable solution.
•
The frequency converter is 100% pre-set for speed open
loop configuration with 0-10 V reference corresponding to
1800 to 5400 RPM for CDS302 and 1500 to 6000 RPM for
CDS303.
utilises and combines Danfoss
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.
4 MG34M302 - VLT® is a registered Danfoss trademark/Commercial Compressor
Introduction
Operating Instructions VLT® CDS302 and CDS303
Oil Injection
•
The frequency converter cycles a solenoid valve
via its relay 1. This ensures that the oil is
distributed to the scroll set, improves tightness,
and reduces internal gas leakage during the
compression process.
Oil Management
•
If the speed of the compressor 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
fixed boosts is limited to a determined amount of
time (within 24 hours).
Discharge Temperature Limit
•
If the discharge temperature exceeds the warning
level of 130 °C, the compressor drops in speed by
10 Hz for the next 3 minutes, then 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 145 °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 to keep the oil
warm and to avoid needing an external crankcase
heater.
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 27 of the frequency converter in
series with the other safety devices.
This alarm will be reset automatically after 30 s and the
compressor will restart.
The necessary start settings, motor data and all the other
preferred settings for each compressor type/size are set up
by the manufacturer and are automatically set up by
selecting the actual compressor in 1-13 Compressor
Selection.
1 1
Sequence of Operation
1.1.1
All compressor types have strong demands to speed limits
to ensure the oil lubrication of the bearings. This is the
main reason for accelerating from standstill to minimum
speed as fast as possible with a special start ramp 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 will be reset automatically after 30 s and
the compressor will restart.
In case of a blocked rotor, 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.
MG34M302 - VLT® is a registered Danfoss trademark/Commercial Compressor 5
Safety Instructions and Gen...
Operating Instructions VLT® CDS302 and CDS303
2 Safety Instructions and General Warnings
22
Compressors
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
fitting of the motor or frequency converter 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.
WARNING
Installation in high altitudes:
By altitudes above 2 km, please contact Danfoss regarding
PELV.
2.1.2 Caution
CAUTION
The CDS302 and CDS303 Compressor Drive™ 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:
CDS302: 11-22 kW 15 minutes
CDS303: High voltage can be present on the DC link even
when the LEDs are turned off.
2.1.3 Disposal
Illustration 2.1
Do not to throw away a used compressor, but dispose of it
and its oil at a specialised recycling company site.
2.1.4 Software Version
CDS302 Operating Instructions Software version: 2.3x
These Operating Instructions can be used for all CDS302
Compressor Drives® with software version 2.3x. The software
version number can be read in 15-43 Software Version.
Table 2.1
CDS303 Operating Instructions Software version: 1.0x
These Operating Instructions can be used for all CDS303
Compressor Drives® with software version 1.0x. The software
version number can be read in 15-43 Software Version.
Table 2.2
Safety Instructions
2.1.5
Make sure that the frequency converter is
•
properly connected to earth
Do not remove mains plugs or motor plugs while
•
the frequency converter is connected to mains
Protect users against supply voltage
•
Protect the motor against overloading according
•
to national and local regulations
Motor overload protection is included in the
•
default settings
The earth leakage current exceeds 3.5 mA
•
The [Off] key is not a safety switch. It does not
•
disconnect the frequency converter from mains
Drive
Equipment containing electrical components may not be
disposed together with domestic waste. It must be
separate collected with Electrical and Electronic Waste
according to local and currently valid legislation.
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Safety Instructions and Gen...
Operating Instructions VLT® CDS302 and CDS303
2.1.6 General Warning
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 CDS302 Compressor Drives®: Wait at least 15
minutes.
Shorter time is allowed only if indicated on the nameplate
for the specific unit.
2.1.7 Leakage Current
CAUTION
The earth leakage current from the frequency converter
exceeds 3.5 mA. To ensure that the earth cable has a good
mechanical connection to the earth connection (terminal
95), the cable cross section must be at least 10 mm2 or 2
times rated earth wires terminated separately.
2.1.8 Residual Current Device
CAUTION
This product can cause a DC current in the protective
conductor. Where a residual current device (RCD) is used
for extra protection, only an RCD of Type B (time delayed)
shall be used on the supply side of this product. See also
RCD Application Note, MN90G. Protective earthing of the
frequency converter and the use of RCDs must always
follow national and local regulations.
2.1.9 IT Mains
the [OFF] key 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 Stop provides a certain
degree of protection against such unintended start, if the
Safe Stop Terminal 37 is on low voltage level or disconnected.
2.2 Safe Stop of the Frequency Converter
The frequency converter can perform the safety function
Safe Torque Off (STO, as defined by EN IEC 61800-5-21) and
Stop Category 0 (as defined in EN 60204-12).
Danfoss has named this functionality Safe Stop. Before
integration and use of Safe Stop in an installation, perform
a thorough risk analysis to determine whether the Safe
Stop functionality and safety levels are appropriate and
sufficient. Safe Stop is designed and approved suitable for
the requirements of:
- 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
1)
Refer to EN IEC 61800-5-2 for details of Safe torque off
(STO) function.
2)
Refer to EN IEC 60204-1 for details of stop category 0
and 1.
Activation and Termination of Safe Stop
The Safe Stop (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 Stop Category 1 can be
obtained. The Safe Stop function can be used for
asynchronous, synchronous, and permanent magnet
motors.
2 2
CAUTION
Do not connect 400 V frequency converters with RFI-filters
to mains supplies with a voltage between phase and earth
of more than 440 V. For IT mains and delta earth
(grounded leg), mains voltage may exceed 440 V between
phase and earth. Use 14-50 RFI 1 on the frequency
converter to disconnect the internal RFI capacitors from
the RFI filter to ground. If this is done, it will reduce 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 or 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
MG34M302 - VLT® is a registered Danfoss trademark/Commercial Compressor 7
WARNING
After installation of Safe Stop (STO), a commissioning test
as specified in section Safe Stop Commissioning Test of the
Design Guide must be performed. A passed commissioning
test is mandatory after first installation and after each
change to the safety installation.
Safe Stop Technical Data
The following values are associated to the different types
of safety levels:
Reaction time for T37
- Typical reaction time: 10 ms
Reaction time = delay between de-energizing the STO
input and switching off the frequency converter output
bridge.
Safety Instructions and Gen...
Operating Instructions VLT® CDS302 and CDS303
Data for EN ISO 13849-1
- Performance Level "d"
22
- 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 test: 9, 20E-14
- PFDavg for five year proof test: 1, 53E-13
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.
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
SIL IEC 61508 Safety Integrity Level
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.
part of safe failures and dangerous
detected failures of a safety function or
a subsystem related to all failures.
Abbrev. Ref. Description
STO EN
61800-5-2
SS1 EN 61800
-5-2
Table 2.3 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
Safe Torque Off
Safe Stop 1
2.2.1 Terminal 37 Safe Stop Function
The frequency converter is available with safe stop
functionality via control terminal 37. Safe stop 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 Stop (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 stop function can
be used as an emergency stop for the frequency converter.
In normal operating mode when safe stop 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 fulfilled.
Liability Conditions
It is the responsibility of the user to ensure that qualified
personnel installs and operates the safe stop 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 Design Guide
Have a good knowledge of the generic and safety
•
standards applicable to the specific application
User is defined as: integrator, operator, service technician,
maintenance technician.
Standards
Use of safe stop on terminal 37 requires that the user
satisfies all provisions for safety including relevant laws,
regulations and guidelines. The optional safe stop function
complies with the following standards.
EN 954-1: 1996 Category 3
•
IEC 60204-1: 2005 category 0 – uncontrolled stop
•
IEC 61508: 1998 SIL2
•
IEC 61800-5-2: 2007 – safe torque off (STO)
•
function
IEC 62061: 2005 SIL CL2
•
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Operating Instructions VLT® CDS302 and CDS303
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 sufficient for a proper and safe use of the safe stop
functionality. The related information and instructions of
the relevant Design Guide must be followed.
Protective Measures
Qualified 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 influence the motor axis (for
•
example, suspended loads), additional measures
are required (for example, a safety holding brake)
to eliminate potential hazards
Safe Stop Installation and Set-Up
safety. Do not use this function as a control for
starting and/or stopping the frequency converter.
Follow these steps to perform a safe installation of the
frequency converter:
1. Remove the jumper wire between control
terminals 37 and 12 or 13. Cutting or breaking
the jumper is not sufficient to avoid shortcircuiting. (See jumper on Illustration 2.2.)
2. Connect an external Safety monitoring relay via a
NO safety function to terminal 37 (safe stop) 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
(EN 954-1)/PL “d” (ISO 13849-1) or SIL 2 (EN
62061).
2 2
WARNING
SAFE STOP FUNCTION!
The safe stop 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 specified in 2.1 Safety and Warnings.
Failure to isolate the mains voltage supply from the unit
and waiting the time specified could result in death or
serious injury.
It is not recommended to stop the frequency
•
converter by using the Safe Torque Off 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 stopping 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 Off function, the system can
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 affected area
of a machine only. It does not provide electrical
Illustration 2.2 Jumper between Terminal 12/13 (24 V) and 37
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Safety Instructions and Gen...
Operating Instructions VLT® CDS302 and CDS303
Example with SS1
SS1 corresponds to a controlled stop, stop category 1
according to IEC 60204-1 (see Illustration 2.5). When
22
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
configured 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.
NOTE
When using the SS1 function, the brake ramp of the
frequency converter is not monitored with respect to
safety.
Illustration 2.3 Installation to Achieve a Stopping Category 0 (EN
60204-1) with Safety Cat. 3 (EN 954-1) / PL “d” (ISO 13849-1) or
SIL 2 (EN 62061).
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 Stop T37 (STO) and the
other by a contactor. Connect the contactor in either the
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 2.4
Safe Stop Commissioning Test
After installation and before first operation, perform a
commissioning test of the installation using safe stop.
Moreover, perform the test after each modification of the
installation.
frequency converter input or output power circuits and
controlled by the Safety relay (see Illustration 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 Stop input the one Safety Relay
Safe Stop 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 (see
Illustration 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
Example with STO
SIL2.
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
Illustration 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 effect can occur, provide
additional measures to prevent any potential movement
(for example mechanical brakes).
NOTE
For all applications with Safe Stop 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).
10 MG34M302 - VLT® is a registered Danfoss trademark/Commercial Compressor
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Safety Instructions and Gen...
Illustration 2.4 STO Example
1 Frequency converter
2 [Reset] key
3 Safety relay
4 Emergency stop
Operating Instructions VLT® CDS302 and CDS303
2 2
Illustration 2.6 STO Category 4 Example
Table 2.5
1 Frequency converter
2 [Reset] key
3 Safety relay
4 Emergency stop
Table 2.7
Illustration 2.5 SS1 Example
1 Frequency converter
2 [Reset] key
3 Safety relay
4 Emergency stop
Table 2.6
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Safety Instructions and Gen...
Operating Instructions VLT® CDS302 and CDS303
The frequency converter is guaranteed not to restart
creation of a rotational field by an internal fault (in
accordance with Cat. 3 of EN 954-1, PL d acc. EN ISO
22
13849-1 and SIL 2 acc. EN 62061). After activation of Safe
Stop, the display shows the text ”Safe Stop activated”. The
associated help text says, "Safe Stop has been activated.
This means that the Safe Stop has been activated, or that
normal operation has not been resumed yet after Safe
Stop activation”.
NOTE
The requirements of Cat. 3 (EN 954-1)/PL “d” (ISO 13849-1)
are only fulfilled while 24 V DC supply to terminal 37 is
kept removed or low by a safety device which itself fulfills
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 brakes.
By default the Safe Stop function is set to an Unintended
Restart Prevention behaviour. Therefore, to resume
operation after activation of Safe Stop,
1. reapply 24 V DC voltage to terminal 37 (text Safe
Stop activated is still displayed)
2. create a reset signal (via bus, Digital I/O, or
[Reset] key.
Illustration 2.7 Paralleling of Multiple Drives Example
The Safe Stop function can be set to an Automatic Restart
Frequency converter
1
2 24 V DC
3 [Reset] key
4 Safety relay
5 Emergency stop
Table 2.8
WARNING
Safe Stop activation (that is removal of 24 V DC voltage
supply to terminal 37) does not provide electrical safety.
The Safe Stop function itself is therefore not sufficient to
implement the Emergency-Off function as defined by EN
60204-1. Emergency-Off requires measures of electrical
isolation, for example, by switching off mains via an
additional contactor.
behaviour. Set the value of 5-19 Terminal 37 Safe Stop from
default value [1] to value [3].
Automatic Restart means that Safe Stop is terminated, and
normal operation is resumed, as soon as the 24 V DC are
applied to Terminal 37. No Reset signal is required.
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 Stop
installation.
2. A presence in the dangerous zone can be
physically excluded when Safe Stop is not
activated. In particular, paragraph 5.3.2.5 of ISO
12100-2 2003 must be observed
1. Activate the Safe Stop function by removing the
24 V DC voltage supply to the terminal 37.
2. After activation of Safe Stop (that is, after the
response time), the frequency converter coasts
(stops creating a rotational field in the motor).
The response time is typically less than 10 ms.
12 MG34M302 - VLT® is a registered Danfoss trademark/Commercial Compressor
Safety Instructions and Gen...
Operating Instructions VLT® CDS302 and CDS303
2.2.2 Safe Stop Commissioning Test
After installation and before first operation, perform a
commissioning test of an installation or application, using
Safe Stop.
Perform the test again after each modification of the
installation or application involving the Safe Stop.
NOTE
A passed commissioning test is mandatory after first 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 Stop is required (that is
Safe Stop only where 5-19 Terminal 37 Safe Stop is set to
default value [1], or combined Safe Stop and MCB 112
where 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 Stop [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 Stop 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 Stop is wanted and
allowed (that is, Safe Stop only where 5-19 Terminal 37
Safe Stop is set to [3], or combined Safe Stop and MCB
112 where 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.
The test step is passed if the motor becomes operational
again. The commissioning test is passed if both test steps
2.1 and 2.2 are passed.
NOTE
See warning on the restart behaviour in 2.2.1 Terminal 37
Safe Stop Function
NOTE
The Safe Stop 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.
NOTE
The Safe Stop function can be used for asynchronous,
synchronous and permanent magnet motors. It may
happen that two faults occur in the frequency converter's
power semiconductor. When using synchronous or
permanent magnet motors this may cause a residual
rotation. The rotation can be calculated to Angle = 360/
(Number of Poles). The application using synchronous or
permanent magnet motors must take this into consideration and ensure that this is not a safety critical issue.
This situation is not relevant for asynchronous motors.
2 2
MG34M302 - VLT® is a registered Danfoss trademark/Commercial Compressor 13
130BT330.10
61
68
39
42
50
53
54
RELAY 1
RELAY 2
03
02
01
06
05
04
130BT346.10
WARNING:
Risk of Electric Shock - Dual supply
Discunnect mains and loadsharing before service
61
68
39
50
53
54
5
42
03
02
01
06
05
04
99
95
130BT347.10
WARNING:
Risk of Electric Shock - Dual supply
Disconnect mains and loadsharing before service
130BA406.10
61 68 6
39 42 50 53 54 5
03 02 01
06 05 04
A
B
C D
E
F
G
H
I
J K
WARNING:
Risk of Electric Shock - Dual supply
Disconnect mains and loadsharing before service
ISOA0021
99
95
61
68
39
50
53
54
5
42
03
02
01
06
05
04
130BT348.10
Risk of Electric Shock - Dual supply
Disconnect mains and loadsharing before service
WARNING:
RELAY 1
RELAY 2
How to Install
3 How to Install
Operating Instructions VLT® CDS302 and CDS303
3
3.1 Environment
3.1.1 Ambient Temperature and Altitude
The normal ambient temperature supported by the CDS is
-10 °C to +50 °C without derating. The CDS operates
normally down to -20 °C with only the LCP display
function impaired but without performance reduction.
For ambient temperatures above +50 °C it is mandatory to
integrate the derating output factor for the maximum
compressor electrical motor power/current.
For altitudes above 1000 m, apply derating as shown in
Table 3.1.
For more details on derating due to environmental factors,
contact Danfoss technical support.
Altitude [m] Derating factor
1000 1
1500 0.95
2000 0.90
2500 0.86
3000 0.82
3500 0.78
Table 3.1 Altitude Derating Factor
Illustration 3.1 Frame Sizes B1 and B2, IP21/IP55/Type 1/Type 12
Illustration 3.2 Frame Size B3, IP20/Chassis
Illustration 3.3 Frame Size B4, IP20/Chassis
Environmental Requirements for
3.1.2
Mechanical Installation
The unit is cooled by means of air circulation.
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 45 °C to 55 °C,
derating will become relevant. The service life of the unit is
reduced if derating for ambient temperature is not taken
Illustration 3.4 Frame Sizes C1 and C2, IP55/66/Type 1/Type 12
into account.
3.2
Mechanical Installation
3.2.1 Accessory Bags
Find the following parts included in the CDS302 Accessory
Bag
14 MG34M302 - VLT® is a registered Danfoss trademark/Commercial Compressor
Illustration 3.5 Frame Size C3, IP20/Chassis
How to Install
Operating Instructions VLT® CDS302 and CDS303
3.2.2 Mechanical Mounting
1. Drill holes in accordance with the measurements
given.
2. Provide screws suitable for the surface on which
the CDS302 is to 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 100 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.
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 3.2 Related VSH Numbers
3
3
MG34M302 - VLT® is a registered Danfoss trademark/Commercial Compressor 15
130BA219.10
A
130BA228.10
A
3
How to Install
Table 3.3
Operating Instructions VLT® CDS302 and CDS303
Frame size B1 Frame size B2 Frame size B3 Frame size B4 Frame size C1 Frame size C3
Height [mm]
Backplate A 480 650 399 520 680 550
Distance between mounting holes a 454 624 380 495 648 521
Width [mm]
Back plate B 242 242 165 230 308 308
Distance between mounting holes b 210 210 140 200 272 270
Depth [mm]
Without option C 260 260 249 242 310 333
With option C 260 260 262 242 310 333
Screw holes
c 12.0 12.0 8 12.0
d Ø 19.0 Ø 19.0 12 Ø 19.0
e Ø 9.0 Ø 9.0 8.8 8.5 Ø 9.0 8.5
f 9.0 9.0 7.9 15 9.8 17
Max. weight [kg] 23.0 27.0 12 23.5 45 50
Table 3.4 Mechanical Dimensions
16 MG34M302 - VLT® is a registered Danfoss trademark/Commercial Compressor
130BT332.10
How to Install
Operating Instructions VLT® CDS302 and CDS303
3.3 Electrical Installation
3.3.1 Cables General
CAUTION
Cables general:
Always comply with national and local regulations on
cable cross-sections.
3
3
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
Table 3.5 Tightening-up Torque
3.3.2
200-240 V
[kW]
380-500 V
[kW]
525-690 V
[kW]
Removal of Knockouts for Extra
Cables
Remove cable entry from the frequency converter
•
(Avoiding foreign parts in the frequency
converter when removing knockouts)
Cable entry has to be supported around the
•
knockout that is to 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
•
Mains Connection for B1, B2 and B3
3.3.3
Cable for Tightening up torque
[Nm]
Mains, Motor cables 1.8
Relay 0.5-0.6
Earth 2-3
Mains 4.5
Motor cables 4.5
Relay 0.5-0.6
Earth 2-3
Mains, Motor cables 1.8
Relay 0.5-0.6
Earth 2-3
Mains, Motor cables 4.5
Relay 0.5-0.6
Earth 2-3
NOTE
Frequency converter sizes differ, but terminal numbers are
always the same. Incoming power is always 91, 92, 93
labeled L1, L2, L3.
MG34M302 - VLT® is a registered Danfoss trademark/Commercial Compressor 17
Illustration 3.6 How to Connect to Mains and Earthing for B1
and B2
130BA725.10
130BA720.10
3
How to Install
Operating Instructions VLT® CDS302 and CDS303
NOTE
For correct cable dimensions see 8 General Specifications.
Illustration 3.7 How to Connect to Mains and Earthing for B3
without RFI.
Illustration 3.8 How to Connect to Mains and Earthing for B3
with RFI.
18 MG34M302 - VLT® is a registered Danfoss trademark/Commercial Compressor
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
95
99
130BA389.10
95
91
L1
92
L2
93
L3
How to Install
Operating Instructions VLT® CDS302 and CDS303
3.3.4 Mains connection for B4, C1 and C3
NOTE
Frequency converter sizes differ but terminal numbers are
always the same. Incoming power is always 91, 92, 93
labeled L1, L2, L3.
3
3
Illustration 3.9 How to Connect to Mains and Earthing for B4.
Illustration 3.10 How to Connect to Mains and Earthing for C1
and C2.
MG34M302 - VLT® is a registered Danfoss trademark/Commercial Compressor 19
91 92 93
91 92 93
96 97 98
88 89
81 82
99
95
130BA718.10
130BC399.10
U
V
W
96
97
98
130BT337.10
130BT333.10
L 1
L 2
L 3
91
92
93
130BT336.10
3
How to Install
Operating Instructions VLT® CDS302 and CDS303
3. Connect to earth 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 labelled MOTOR.
5. Fasten screened cable to decoupling plate with
screws and washers from the accessory bag.
6. U, V, W for motor compressor need to be
clockwise connected.
Illustration 3.11 How to Connect C3 to Mains and Earthing.
Motor Compressor Connection
3.3.5
NOTE
Always wire terminal 96 (U) to T1, 97 (V) to T2, and 98 (W)
to T3.
Illustration 3.12 Motor/Compressor Wiring
Illustration 3.13
Illustration 3.14
Motor compressor cable must be screened/armoured. If an
Illustration 3.15
unscreened/unarmoured cable is used, some EMC
requirements are out of compliance. For more information,
see EMC specifications.
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
20 MG34M302 - VLT® is a registered Danfoss trademark/Commercial Compressor
(U), 97 (V), 98 (W).
130BT248.10
130BT334.10
How to Install
Operating Instructions VLT® CDS302 and CDS303
3.3.6 Motor Compressors Cables
Correct dimensioning of motor compressor cable crosssection and length is described in the application manual.
Use a screened/armoured motor compressor
•
cable to comply with EMC emission specifications
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). This is done
by using the supplied installation devices in the
frequency converter.
Electrical Installation of Motor
3.3.7
Compressor Cables
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
•
earth faults on compressor motor terminals T1,
T2, T3.
Access to Control Terminals
3.3.9
3
3
Screening of cables
Avoid installation with twisted screen ends (pigtails). They
reduce the screening effect 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.
Aluminium conductors
Aluminium conductors are not recommended. Terminals
can accept aluminium conductors but the conductor
surface has to be clean and the oxidation must be
removed and sealed by neutral acid free 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 will oxidize again.
3.3.8
Compressor Motor Protection
Illustration 3.16 B3, B4 and C3 Enclosures
The electrical compressor motor protection is fully
provided by the frequency converter.
•
The frequency converter makes through an
Electronic current measurement anti-overload and
MG34M302 - VLT® is a registered Danfoss trademark/Commercial Compressor 21
Illustration 3.17 C1, B1 and B2 Enclosures
1. 10 pole plug digital I/O
2. 3 pole plug RS485 Bus
1
4
2
3
130BA012.11
61
68
69
39
42
50
53
54
55
12
13
18
19
27
29
32
33
20
37
130BT312.10
130BT311.10
130BA150.10
9 - 10 mm
(0.37 in)
130BT306.10
How to Install
Operating Instructions VLT® CDS302 and CDS303
3
3. 6 pole analog I/O
4. USB Connection
Control terminals are located beneath the LCP. The inside
of the removable cover shows the terminals.
Illustration 3.18 Control Terminals
1. Insert a screwdriver in the square hole.
2. Pull out the cable
Illustration 3.20
To mount the cable to the terminal:
1. Strip isolation of 9-10 mm
2. Insert a screwdriver in the square hole.
Illustration 3.21
3. Insert the cable in the adjacent circular hole.
4. Remove the screwdriver. The cable is now
mounted to the terminal
3.3.10 Basic Wiring Example
1. Mount terminals from the accessory bag to the
front of the frequency converter.
Illustration 3.22
Illustration 3.19
To remove the cable from the terminal:
22 MG34M302 - VLT® is a registered Danfoss trademark/Commercial Compressor
2. Connect terminals 18, 27 and 37 to +24 V
(terminal 12/13)
Default settings:
18 = start
27 = coast inverse
12 13 18 37
130BA156.12
322719 29 33 20
P 5 - 12 [6]
P 5 - 10[9]
+24V
Speed
Start Stop inverse Safe Stop
Start (18)
Start (27)
How to Install
Operating Instructions VLT® CDS302 and CDS303
3
3
Illustration 3.23
MG34M302 - VLT® is a registered Danfoss trademark/Commercial Compressor 23
3 Phase
power
input
DC bus
Switch Mode
Power Supply
Motor
Analog Output
Interface
relay1
relay2
(PNP) = Source
(NPN) = Sink
ON=Terminated
OFF=Open
Brake
resistor
130BA025.19
91 (L1)
92 (L2)
93 (L3)
PE
88 (-)
89 (+)
50 (+10 V OUT)
53 (A IN)
54 (A IN)
55 (COM A IN)
0/4-20 mA
12 (+24V OUT)
13 (+24V OUT)
37 (D IN)
18 (D IN)
20 (COM D IN)
10Vdc
15mA 130/200mA
+ - + -
(U) 96
(V) 97
(W) 98
(PE) 99
(COM A OUT) 39
(A OUT) 42
(P RS-485) 68
(N RS-485) 69
(COM RS-485) 61
0V
5V
S801
0/4-20 mA
RS-485
RS-485
03
+10Vdc
-10Vdc -
+10Vdc
+10Vdc
0/4-20 mA
-10Vdc -
240Vac, 2A
24Vdc
02
01
05
04
06
240Vac, 2A
24V (NPN)
0V (PNP)
0V (PNP)
24V (NPN)
19 (D IN)
24V (NPN)
0V (PNP)
27
24V
0V
(D IN/OUT)
0V (PNP)
24V (NPN)
(D IN/OUT)
0V
24V
29
24V (NPN)
0V (PNP)
0V (PNP)
24V (NPN)
33 (D IN)
32 (D IN)
1 2
ON
S201
ON
21
S202
ON/I=0-20mA
OFF/U=0-10V
95
400Vac, 2A
P 5-00
21
ON
S801
(R+) 82
(R-) 81
*
*
How to Install
Operating Instructions VLT® CDS302 and CDS303
3
3.3.11 Electrical Installation, Control Cables
Terminal 37 is the input to be used for Safe Stop. Control
cables more than 100 m (330 ft) and analog signals may in
rare cases and depending on installation result in 50/60 Hz
earth loops due to noise from mains supply cables. If this
occurs, break the screen or insert a 100 nF capacitor
between screen and chassis. The digital and analog in- and
outputs must be connected separately to the frequency
converter common inputs (terminal 20, 55, 39) to avoid
ground currents from both groups to affect other groups.
Illustration 3.24
24 MG34M302 - VLT® is a registered Danfoss trademark/Commercial Compressor
130BT340.10
PE
FC
PE
130BA051.11
PE PE
FC
PE PE
FC
100nF
PE
FC
69
FC
PE PE
PE
68
61
68
69
FC
PE
a
b
c
d
e
PLC etc.
PLC etc.
PLC etc.
PLC etc.
Equalizing cable
Min. 16mm
2
How to Install
Operating Instructions VLT® CDS302 and CDS303
Control cables must be screened/armoured. Use a clamp
from the accessory bag to connect the screen to the
frequency converter decoupling plate for control cables.
Illustration 3.25
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 earth via an
internal RC link. Use twisted-pair cables to reduce the
differential mode interference between the conductors.
3
3
Generally speaking, control cables must be braided
screened/armoured and the screen must be connected by
means of a cable clamp at both ends to the metal cabinet
of the unit. The drawing indicates how correct earthing is
carried out and what to do if in doubt.
a. Correct earthing
Control cables and cables for serial communication must
be fitted with cable clamps at both ends to ensure the
best possible electrical contact.
b. Wrong earthing
Do not use twisted cable ends (pigtails). They increase the
screen impedance at high frequencies.
c. Protection with respect to earth potential between
PLC(Program Logic Controller) and frequency converter
If the earth potential between the frequency converter and
the PLC (etc.) is different, electric noise may occur that will
disturb the entire system. Solve this problem by fitting an
equalising cable, next to the control cable. Minimum cable
cross-section: 16 mm2.
d. For 50/60 Hz earth loops
If very long control cables are used, 50/60 Hz earth loops
may occur. Solve this problem by connecting one end of
Illustration 3.26
the screen to earth via a 100 nF capacitor (keeping leads
short).
MG34M302 - VLT® is a registered Danfoss trademark/Commercial Compressor 25
How to Install
Operating Instructions VLT® CDS302 and CDS303
3
3.3.12 Electrical Installation - EMC
Protection
The following is a guideline to good engineering practice
when installing frequency converters. Follow these
guidelines to comply with EN 61800-3 First environment. 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/armoured motor
•
compressor cables and braided screened/
armoured control cables. The screen should
provide a minimum coverage of 80%. The screen
material must be metal, not limited to but
typically copper, aluminium, 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 flexible conduits varies a
lot and information from the manufacturer must
be obtained.
Connect the screen/armour/conduit to earth 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
3.3.11 Electrical Installation, Control Cables.
Avoid terminating the screen/armour with twisted
•
ends (pigtails). It increases the high frequency
impedance of the screen, which reduces its
effectiveness at high frequencies. Use low
impedance cable clamps or EMC cable glands
instead.
Avoid using unscreened/unarmoured motor
•
compressor or control cables inside cabinets
housing the frequency converter(s), whenever this
can be avoided.
Leave the screen as close to the connectors as possible.
Illustration 3.27 shows an example of an EMC-correct
electrical installation of an IP 20 frequency converter.
The frequency converter is fitted 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. If the installation is not carried out according to
the guideline and if unscreened cables and control wires
are used, some emission requirements are not complied
with, although the immunity requirements are fulfilled. See
the paragraph.
26 MG34M302 - VLT® is a registered Danfoss trademark/Commercial Compressor
How to Install
Operating Instructions VLT® CDS302 and CDS303
3
3
Illustration 3.27 EMC Correct Installation of an IP20 Frequency Converter
3.3.13
The frequency converter has a high leakage current and
must be earthed appropriately for safety reasons according
to EN 50178. The earth leakage current from the frequency
converter exceeds 3.5 mA. To ensure a good mechanical
connection from the earth cable to the earth connection
(terminal 95), the cable cross-section must be at least 10
mm2 or 2 rated earth wires terminated separately.
Safety Earth Connection
MG34M302 - VLT® is a registered Danfoss trademark/Commercial Compressor 27
130BC398.10
3
How to Install
Operating Instructions VLT® CDS302 and CDS303
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.
Illustration 3.28
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.
Illustration 3.29
28 MG34M302 - VLT® is a registered Danfoss trademark/Commercial Compressor
How to Install
Operating Instructions VLT® CDS302 and CDS303
3.3.15 High Voltage Test
Carry out a high voltage test by short-circuiting terminals
U, V, W, L1, L2 and L3. Energize by max. 2.15 kV DC for
one second between this short-circuit and the chassis.
NOTE
When running high voltage tests of the entire installation,
frequency converter and compressor electrical motor
compressor test can be conducted together.
WARNING
When conducting a high voltage test make sure the
system is not under vacuum: this may cause electrical
motor compressor failure.
WARNING
Never apply the high voltage test to the control circuit.
3.4 Fuses and Circuit Breakers
3.4.1 Fuses
3.4.2
Recommendations
WARNING
In case of malfunction, ignoring recommended fuse types
may result in personnel risk and damage to the frequency
converter and other equipment.
The following tables list the recommended rated current.
Recommended fuses are of the type gG for small to
medium power sizes. For larger powers, aR fuses are
recommended. For circuit breakers, Moeller types have
been tested to have a recommendation. Other types of
circuit breakers may be used provide they limit the energy
into the to a level equal to or lower than the Moeller
types.
For further information, see Application Note Fuses and
Circuit Breakers, MN90T
3
3
NOTE
Use fuses and/or circuit breakers on the supply side of the
unit for protection of electrical components within the
frequency converter in order to ensure compliance with
IEC 60364 for CE or NEC 2009 for UL.
WARNING
Personnel and property must be protected against the
consequence of component break-down internally in the
frequency converter.
Branch Circuit Protection
To protect the installation against electrical and fire hazard,
all branch circuits in an installation, switch gear, machines
etc., must be protected against short-circuit and overcurrent according to national/international regulations.
NOTE
The recommendations given do not provide UL branch
circuit protection.
Danfoss recommends using the fuses/circuit breakers listed
below to protect service personnel and property in case of
component break-down in the frequency converter.
MG34M302 - VLT® is a registered Danfoss trademark/Commercial Compressor 29
How to Install
Operating Instructions VLT® CDS302 and CDS303
3
3.4.3 CE Compliance
The fuses below are suitable for use on a circuit capable of
delivering 100,000 Arms (symmetrical), 240V, 480V, 500V,
Fuses or circuit breakers are mandatory to comply with IEC
60364. Danfoss recommends using a selection of the
following.
Enclosure Power Recommended
fuse size
Size [kW] Moeller [A]
B1 5.5-7.5 gG-25 (5.5)
gG-32 (7.5)
B2 11 gG-50 gG-100 NZMB1-A100 100
B3 5.5 gG-25 gG-63 PKZM4-50 50
B4 7.5-15 gG-32 (7.5)
gG-50 (11)
gG-63 (15)
C1 15-22 gG-63 (15)
gG-80 (18.5)
gG-100 (22)
C2 30-37 aR-160 (30)
aR-200 (37)
C3 18.5-22 gG-80 (18.5)
aR-125 (22)
C4 30-37 aR-160 (30)
aR-200 (37)
or 600V depending on the unit's voltage rating. With the
proper fusing, the frequency converter short circuit current
rating (SCCR) is 100,000 Arms.
Recommended
Max. fuse
gG-80 PKZM4-63 63
gG-125 NZMB1-A100 100
gG-160 (15-18.5)
aR-160 (22)
aR-200 (30)
aR-250 (37)
gG-150 (18.5)
aR-160 (22)
aR-200 (30)
aR-250 (37)
Recommended circuit
breaker
NZMB2-A200 160
NZMB2-A250 250
NZMB2-A200 150
NZMB2-A250 250
Max trip level
Table 3.6 200-240 V, Frame Sizes B and C
Enclosure Power Recommended
fuse size
Size [kW] Moeller [A]
B1 11-15 gG-40 gG-80 PKZM4-63 63
B2 18.5-22 gG-50 (18.5)
gG-63 (22)
B3 11-15 gG-40 gG-63 PKZM4-50 50
B4 18.5-30 gG-50 (18.5)
gG-63 (22)
gG-80 (30)
C1 30-45 gG-80 (30)
gG-100 (37)
gG-160 (45)
C2 55-75 aR-200 (55)
aR-250 (75)
C3 37-45 gG-100 (37)
gG-160 (45)
C4 55-75 aR-200 (55)
aR-250 (75)
Table 3.7 380-500 V, Frame Sizes B and C
Recommended
Max. fuse
gG-100 NZMB1-A100 100
gG-125 NZMB1-A100 100
gG-160 NZMB2-A200 160
aR-250 NZMB2-A250 250
gG-150 (37)
gG-160 (45)
aR-250 NZMB2-A250 250
Recommended circuit
breaker
NZMB2-A200 150
Max trip level
30 MG34M302 - VLT® is a registered Danfoss trademark/Commercial Compressor
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