MAKING MODERN LIVING POSSIBLE
Quick Guide
VLT® Compressor Drive CDS 803
www.danfoss.com/drives
Contents
1 Quick Guide
2
1.1 Safety
2
1.1.1 Warnings 2
1.1.2 Safety Instructions 2
1.2 Introduction
2
1.2.1 Available Literature 2
1.2.2 Approvals 3
1.2.3 IT Mains 3
1.2.4 Avoid Unintended Start 3
1.2.5 Disposal Instruction 3
1.3 Installation
3
1.3.1 Before Starting Repair Work 3
1.3.2 Enclosure Types 3
1.3.3 Side-by-Side Installation 4
1.3.4 Dimensions 4
1.3.6 Connecting to Mains and Compressor 5
1.3.7 Fuses 7
1.3.8 EMC-Correct Electrical Installation 8
1.3.9 Control Terminals 9
1.4 Programming
11
1.4.2 The Start-up Wizard 12
1.4.3 Main Menu Structure 21
1.5 Acoustic Noise or Vibration
23
1.6 Warnings and Alarms
23
1.7 General Specifications
24
1.7.1 Mains Supply 3x200-240 V AC 24
1.7.2 Mains Supply 3x380-480 V AC 25
1.8 Special Conditions
29
1.8.1 Derating for Ambient Temperature and Switching Frequency 29
1.8.2 Derating for Low Air Pressure 29
1.9 Options for VLT® Compressor Drive CDS 803
29
Contents Quick Guide
MG18M102 Danfoss A/S © Rev. 09/2014 All rights reserved. 1
1 Quick Guide
1.1 Safety
1.1.1 Warnings
WARNING
High Voltage Warning
The voltage of the frequency converter is dangerous
whenever it is connected to mains. Incorrect installation
of the compressor 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
DISCHARGE TIME!
Frequency converters contain DC-link capacitors that can
remain charged even when the frequency converter is
not powered. To avoid electrical hazards, disconnect AC
mains, any permanent magnet type compressors, and
any remote DC-link power supplies, including battery
back-ups, UPS, and DC-link connections to other
frequency converters. Wait for the capacitors to fully
discharge before performing any service or repair work.
The waiting time is listed in the Discharge Time table.
Failure to wait the specified time after power has been
removed before doing service or repair could result in
death or serious injury.
Voltage [V] Cooling capacity [TR] Minimum waiting time
(min)
3x200 4-6.5 15
3x400 4-5 4
3x400 6.5 15
Table 1.1 Discharge Time
CAUTION
Leakage Current
The ground leakage current from the frequency
converter exceeds 3.5 mA. According to IEC 61800-5-1 a
reinforced Protective Earth connection must be ensured
with a min. 10 mm2 Cu or an additional PE wire - with
the same cable cross-section as the mains wiring - must
be terminated separately.
Residual Current Device
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 Danfoss Application Note on RCD,
MN90G.
Protective earthing of the frequency converter and the
use of RCDs must always follow national and local
regulations.
WARNING
Installation at High Altitudes
For altitudes above 2000 m, contact Danfoss regarding
PELV.
1.1.2 Safety Instructions
•
Make sure the frequency converter is properly
connected to ground.
•
Do not remove mains connections, compressor
connections or other power connections while
the frequency converter is connected to power.
•
Protect users against supply voltage.
•
Protect the compressor against overloading
according to national and local regulations.
•
The ground leakage current exceeds 3.5 mA.
•
The [Off/Reset] key is not a safety switch. It does
not disconnect the frequency converter from
mains.
1.2
Introduction
1.2.1 Available Literature
This Quick Guide contains basic information necessary for
installing and running the frequency converter. Supplementary publications and manuals are available from
Danfoss. See www.danfoss.com/BusinessAreas/DrivesSo-
lutions/ Documentations/VLT+Technical+Documentation.htm
for listings.
Quick Guide
Quick Guide
2 Danfoss A/S © Rev. 09/2014 All rights reserved. MG18M102
1
1.2.2 Approvals
Certification IP20
EC Declaration of
Conformity
✓
UL Listed
✓
C-tick
✓
Table 1.2 Approvals
The frequency converter complies with UL508C thermal
memory retention requirements. For more information,
refer to the section Motor Thermal Protection in the
product specific design guide.
1.2.3
IT Mains
CAUTION
IT Mains
Installation on isolated mains source, that is, IT mains.
Max. supply voltage allowed when connected to mains:
440 V (3x380-480 V units).
Open the RFI switch by removing the screw on the side of
the frequency converter when at IT grid.
130BB612.10
1
1
RFI switch
Illustration 1.1 IP20
CAUTION
If reinserted, only use M3x12 screw.
1.2.4 Avoid Unintended Start
While the frequency converter is connected to mains, the
compressor can be started/stopped using digital
commands, bus commands, references or via the LCP.
•
Disconnect the frequency converter from mains
whenever personal safety considerations make it
necessary to avoid unintended start of any
compressors.
•
To avoid unintended start, always press [Off/
Reset] before changing parameters.
1.2.5
Disposal Instruction
Equipment containing electrical components
must not be disposed of together with domestic
waste.
It must be separately collected with electrical
and electronic waste according to local and
currently valid legislation.
1.3 Installation
1.3.1 Before Starting Repair Work
1. Disconnect from mains (and external DC supply, if
present).
2.
Wait as stated in Table 1.1 for discharge of the
DC-link.
3. Remove compressor cable.
1.3.2
Enclosure Types
Cooling capacity 400 V IP20
Enclosure
4 TR/VZH028 H3
5 TR/VZH035 H3
6.5 TR/VZH044 H4
Table 1.3 H3-H4, 400 V
Cooling capacity 200 V IP20
Enclosure
4 TR/VZH028 H4
5 TR/VZH035 H4
6.5 TR/VZH044 H5
Table 1.4 H4-H5, 200 V
Quick Guide
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MG18M102 Danfoss A/S © Rev. 09/2014 All rights reserved. 3
1
1
1.3.3 Side-by-Side Installation
The frequency converter can be mounted side-by-side and requires the clearance above and below for cooling.
Frame IP class Clearance above/below [mm/inch]
H3 IP20 100/4
H4 IP20 100/4
H5 IP20 100/4
Table 1.5 Clearance
NOTICE
With IP21/Nema Type1 option kit mounted, a distance of 50 mm between the units is required.
1.3.4 Dimensions
NOTICE
The illustration in Table 1.6 is with LCP, but all
dimensions are the same without LCP.
A
a
b
B
C
D
130BB614.10
e
f
a
e
130BC246.10
Enclosure Height [mm] Width [mm] Depth [mm] Mounting hole [mm] Max.
Weight
Frame IP Class A
A
1)
a B b C d e f kg
H3 IP20 255 329 240 100 74 206 11 5.5 8.1 4.5
H4 IP20 296 359 275 135 105 241 12.6 7 8.4 7.9
H5 IP20 334 402 314 150 120 255 12.6 7 8.5 9.5
Table 1.6 Dimensions
1) Including decoupling plate
The dimensions are only for the physical units, but when installing in an application it is necessary to add space for free air
passage both above and below the units. The amount of space for free air passage is listed in Table 1.5.
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4 Danfoss A/S © Rev. 09/2014 All rights reserved. MG18M102
1
1.3.5 Electrical Installation in General
All cabling must comply with national and local regulations on cable cross-sections and ambient temperature. Copper
conductors required, (75 °C) recommended.
Enclosure Torque [Nm]
Frame IP class Line Compressor
connection
DC connection Control
terminals
Ground Relay
H3 IP20 1.4 0.8 0.8 0.5 0.8 0.5
H4 IP20 1.2 1.2 1.2 0.5 0.8 0.5
H5 IP20 1.2 1.2 1.2 0.5 0.8 0.5
Table 1.7 Enclosure H3-H5
1.3.6
Connecting to Mains and Compressor
The frequency converter is designed to operate Danfoss
VZH Compressors. For maximum cross-section on wires see
chapter 1.7 General Specifications.
•
Use a shielded/armored compressor cable to
comply with EMC emission specifications, and
connect this cable to both the decoupling plate
and the compressor metal.
•
Keep compressor cable as short as possible to
reduce the noise level and leakage currents.
•
For further details on mounting of the
decoupling plate, see VLT® Compressor Drive CDS
803 Decoupling Plate Installation Instructions.
•
Also see EMC-Correct Installation in the VLT
®
Compressor Drive CDS 803 Design Guide.
1. Mount the ground wires to ground terminal.
2. Connect compressor to terminals U, V and W, see
Table 1.8.
U
T1
V T2
W T3
Table 1.8 Connection of Compressor to Terminals
3. Mount mains supply to terminals L1, L2 and L3
and tighten.
130BB634.10
1
2
2
3
4
Motor
U
V
W
-DC
+DC
MAINS
1
Line
2 Ground
3 Compressor
4 Relays
Illustration 1.2 H3-H5 Frame
IP20 200-240 V 4-6.5 tons
IP20 380-480 V 4-6.5 tons
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MG18M102 Danfoss A/S © Rev. 09/2014 All rights reserved. 5
1
1
-DC+DC
BR- BR+ U V W
99
M A I N S
95
RELAY 1 RELAY 2
- LC +
130BA261.10
Illustration 1.3 Mount the 2 screws in the mounting plate,
slide it into place and tighten fully.
MOTOR
MOTOR
U V W
99
130BT302.12
Illustration 1.4 H3-H5 Frame
130BA262.10
M
I N S
+DC
BR-
BR+
U
V
W
RELAY 1 RELAY 2
95
Illustration 1.5 When mounting cables, first mount and tighten
ground cable.
130BA263.10
95
M
A
INS
+DC
BR-
BR+
U
V
W
91
92
93
L1
L2
L3
RELAY 1 RELAY 2
Illustration 1.6 Mount mains plug and tighten wires.
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6 Danfoss A/S © Rev. 09/2014 All rights reserved. MG18M102
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+DC
BR-
BR+
U
V
W
MAINS
L1 L2 L3
91 92 93
RELAY 1 RELAY 2
99
- LC -
130BA264.10
Illustration 1.7 Tighten support bracket on mains wires.
1.3.7
Fuses
Branch circuit protection
To protect the installation against electrical and fire hazard, all branch circuits in an installation, switch gear, machines etc.,
must be short-circuit and overcurrent protected according to national and local regulations.
Short circuit protection
Danfoss recommends using the fuses listed in Table 1.9 to protect service personnel or equipment in case of an internal
failure in the unit or short-circuit on DC-link. The frequency converter provides full short circuit protection in case of a shortcircuit on the compressor.
Overcurrent protection
Provide overload protection to avoid overheating of the cables in the installation. Overcurrent protection must always be
carried out according to local and national regulations. Circuit breakers and fuses must be designed for protection in a
circuit capable of supplying a maximum of 100,000 A
rms
(symmetrical), 480 V maximum.
UL/Non UL compliance
Use the fuses listed in Table 1.9 to ensure compliance with UL or IEC 61800-5-1.
NOTICE
In the event of malfunction, failure to follow the protection recommendation may result in damage to the frequency
converter.
Fuse
UL Non UL
Bussmann Bussmann Bussmann Bussmann Max fuse
CDS 803 Type RK5 Type RK1 Type J Type T Type G
3x200-240 V IP20
4 TR/VZH028 FRS-R-50 KTN-R50 JKS-50 JJN-50 50
5 TR/VZH035 FRS-R-50 KTN-R50 JKS-50 JJN-50 50
6.5 TR/VZH044 FRS-R-80 KTN-R80 JKS-80 JJN-80 65
3x380-480 V IP20
4 TR/VZH028 FRS-R-25 KTS-R25 JKS-25 JJS-25 25
5 TR/VZH035 FRS-R-25 KTS-R25 JKS-25 JJS-25 25
6.5 TR/VZH044 FRS-R-50 KTS-R50 JKS-50 JJS-50 50
Table 1.9 Fuses
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MG18M102 Danfoss A/S © Rev. 09/2014 All rights reserved. 7
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1.3.8 EMC-Correct Electrical Installation
General points to be observed to ensure EMC-correct electrical installation.
•
Use only screened/armoured motor cables and screened/armoured control cables.
•
Connect the screen to ground at both ends.
•
Avoid installation with twisted screen ends (pigtails), since this ruins the screening effect at high frequencies. Use
the cable clamps provided instead.
•
Ensure the same potential between frequency converter and ground potential of PLC.
•
Use starwashers and galvanically conductive installation plates.
B
a
c
k
OK
Com.
On
Warn.
Alarm
Hand
On
O
Reset
Auto
On
Menu
Status Quick
Menu
Main
Menu
L1
L2
L3
PE
Min. 16 mm
2
Equalizing cable
Control cables
All cable entries in
one side of panel
Earthing rail
Cable insulation stripped
Output contactor etc.
Motor cable
Motor, 3 phases and
PLC etc.
Panel
Mains-supply
Min. 200mm
between control
cable, mains cable
and between mains
motor cable
PLC
Protective earth
Reinforced protective earth
130BB761.11
Illustration 1.8 EMC-correct Electrical Installation
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8 Danfoss A/S © Rev. 09/2014 All rights reserved. MG18M102
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