Danfoss VLT CDS 803 Bedienungsanleitung

Design Guide

VLT® Compressor Drive CDS 803

6–30 kW

vlt-drives.danfoss.com

1.1

1.2

1.2.1

1.2.2

1.3

1.4

2.1

2.2

2.3

3.1

3.2

3.2.1

3.2.1.1

3.2.1.2

3.2.1.3

3.2.1.4

3.2.1.5

3.2.1.6

3.2.1.7

3.2.2

3.2.2.1

3.2.2.2

3.2.2.3

3.2.2.4

3.2.2.5

3.2.2.6

3.2.2.7

3.2.2.8

3.2.2.9

3.2.2.9.1

3.2.2.9.2

3.3

Contents

Introduction 7

Purpose of this Design Guide 7

Additional Resources 7

Supplementary Documentation 7

VLT® Motion Control Tool MCT 10 Software Support 7

Manual and Software Version 7

Approvals and Certifications 7

Safety 9

Safety Symbols 9

Qualified Personnel 9

Safety Precautions 9

Product Overview 11

VLT® Compressor Drive CDS 803 Family Overview 11

VLT® Compressor Drive CDS 803 Features 12

Compressor Features 12

Secure Start-up 12

Compressor Minimum Speed Detection 13

Short-cycle Protection 14

Anti-reverse Protection 14

Oil Return Management 15

Data Readouts and Commissioning 15

Undersized Compressor 16

Application Features 16

Automatic Motor Adaptation (AMA) 16

Motor Thermal Protection 16

Built-in PID Controller 17

Automatic Restart 17

Flying Start 17

Frequency Bypass 17

Motor Preheat 17

Programmable Set-ups 18

Smart Logic Control (SLC) 18

Comparators 19

Logic Rules 19

VLT® Compressor Drive CDS 803 Protections 19

Contents

VLT® Compressor Drive CDS 803

Design Guide

3.3.1

3.3.1.1

3.3.1.2

3.3.2

3.3.2.1

3.3.2.2

3.3.2.3

3.3.2.4

3.3.2.5

3.3.3

3.3.3.1

3.3.3.2

3.3.3.3

3.3.4

3.3.4.1

3.3.4.2

3.4

3.4.1

3.4.2

3.4.3

3.4.4

3.4.5

3.4.6

4.1

4.1.1

4.1.2

4.2

4.3

4.4

4.4.1

4.4.2

4.4.3

4.4.4

4.4.5

4.4.6

4.4.7

Mains Input Protection 19

Mains Supply Failure, Momentary Dropouts, and Surges 19

Missing Mains Phase Detection 20

Output Protection 20

Short-circuit Protection (Phase-to-phase) 20

Ground Fault Protection (Output Phase-to-Ground) 20

Locked Rotor Detection 20

Output Phase Loss Detection 20

Overload Protection 20

Temperature Protection 21

Minimum and Maximum Temperature Protection 21

Automatic Temperature Derating 21

Temperature-controlled Fans 21

Internal Protection 21

DC Overvoltage Protection 21

Internal Faults 21

Ecodesign for Power Drive Systems 21

Losses in Mains Cabling 23

Input Filters: Line Reactors and Harmonic Filters 23

Drive, Input Side 24

DC Link 24

Drive, Output Side 25

Motor Cables and Motor 26

Specifications 27

Electrical Data 27

Electrical Data 3x200–240 V AC 27

Electrical Data 3x380–480 V AC 27

Mains Supply (L1, L2, L3) 28

Compressor Output (U, V, W) 28

Control Input/Output 29

10 V DC Output 29

24 V DC Output 29

Analog Inputs 29

Analog Outputs 29

Digital Inputs 29

Digital Outputs 30

Relay Outputs, Enclosure Sizes H3–H5 30

Contents

VLT® Compressor Drive CDS 803

Design Guide

4.4.8

4.4.9

4.5

4.6

4.7

4.8

4.9

4.9.1

4.9.2

4.10

5.1

5.1.1

5.2

5.3

5.3.1

5.3.2

5.3.3

5.3.4

5.3.5

5.3.5.1

5.3.5.2

5.3.5.3

5.3.6

5.4

5.5

5.6

6.1

6.1.1

6.2

6.2.1

6.3

6.3.1

6.3.2

6.3.3

6.3.4

Relay Outputs, Enclosure Size H6 30

RS485 Serial Communication 31

Ambient Conditions 31

Conforming Standards 32

Cable Lengths and Cross-sections 32

Acoustic Noise 32

Mechanical Dimensions 33

Drive Dimensions 33

Shipping Dimensions 34

dU/dt 34

Mechanical Installation Considerations 36

Safe Transportation and Storage 36

Reforming the Capacitors 36

Side-by-side Installation 37

Operating Environment 37

Gases 38

Dust 38

Air Humidity 39

Vibration and Shock 39

Derating for Ambient Temperature and Switching Frequency 39

Derating Curves, 6.0, 7.5, and 10 kW 39

Derating Curves, 18.5–22 kW 40

Derating Curves, 30 kW 40

Derating for Low Air Pressure and High Altitudes 41

IP21/NEMA Type 1 Enclosure Kit 41

Acoustic Noise or Vibration 43

Recommended Disposal 43

Electrical Installation Considerations 45

Electrical Installation in General 45

Fastener Torque Ratings 45

Fuses and Circuit Breakers 45

Recommendation of Fuses and Circuit Breakers 45

Electrical Wiring 46

Wiring Schematic 46

Terminal Overview of Enclosure Sizes H3–H5 47

Terminal Overview of Enclosure Size H6 48

Connecting to Mains and Compressor Terminals 48

Contents

VLT® Compressor Drive CDS 803

Design Guide

6.3.4.1

6.3.5

6.3.6

6.4

6.5

6.5.1

6.5.2

6.5.3

6.5.4

6.5.5

6.5.6

6.5.7

6.5.8

6.6

6.6.1

6.6.2

6.7

6.8

6.8.1

7.1

7.2

7.3

8.1

8.2

IT Grid Installations 49

Relay Terminals 49

Control Terminals 50

Setting Up RS485 Serial Communication 51

Electromagnetic Compatibility 52

EMC Emission Test Results 53

Emission Requirements 53

Immunity Requirements 54

EMC Compatibility 56

EMC-compliant Electrical Installation 57

EMC-compliant Cables 59

Shielded Control Cables 60

RFI Filter Switch 61

Harmonics Emission 61

Harmonics Emission Requirements 62

Harmonics Test Results (Emission) 62

Galvanic Isolation (PELV) 63

Ground Leakage Current 63

Using a Residual Current Device (RCD) 65

How to Order 67

Drive Configurator 67

Type Code Description 67

Accessories and Spare Parts 68

Appendix 69

Abbreviations 69

Conventions 69

Contents

VLT® Compressor Drive CDS 803

Design Guide

•

1 Introduction

1.1 Purpose of this Design Guide

This Design Guide is intended for qualified personnel, such as:

Project and systems engineers.

Design consultants.

Application and product specialists.

The Design Guide provides technical information to understand the capabilities of the VLT® Compressor Drive CDS 803 for integra-

tion into motor control and monitoring systems. Its purpose is to provide design considerations and planning data for integration of

the drive into a system. It caters for selection of drives and options for a diversity of applications and installations. Reviewing the

detailed product information in the design stage enables developing a well-conceived system with optimal functionality and effi-

ciency.

This manual is targeted at a worldwide audience. Therefore, wherever occurring, both SI and imperial units are shown.

VLT®is a registered trademark for Danfoss A/S.

1.2 Additional Resources

1.2.1 Supplementary Documentation

Various resources are available to understand advanced drive operation, programming, and directives compliance.

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

The Operating Guide provides detailed information about installation and commissioning of the drive.

See www.danfoss.com for supplementary documentation.

1.2.2 VLT® Motion Control Tool MCT 10 Software Support

Download the software from the Service and Support download page on www.danfoss.com.

During the installation process of the software, enter CD-key 34544400 to activate the CDS 803 functionality. An activation key is not

required for using the CDS 803 functionality.

The latest software does not always contain the latest updates for the drive. Contact the local sales office for the latest drive updates

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

1.3 Manual and Software Version

This manual is regularly reviewed and updated. All suggestions for improvement are welcome.

Table 1: Manual and Software Version

Edition

Remarks

Software version

AJ330233902305, version 0201

Software update for 18–30 kW (25–40 hp) drives.

6.0–10 kW (8–15 hp): Version 2.0

18–30 kW (25–40 hp): Version 61.20

1.4 Approvals and Certifications

Description

Conformity mark

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

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

(RoHS)

Countries of use: Europe

ACMA Declaration of Conformity (RCM - Regulatory Compliance Mark)

Australian Communications Media Authority (ACMA)

Low Voltage Directive/Electromagnetic compatibility (EMC)

Countries of use: Australia and New Zealand

Introduction

VLT® Compressor Drive CDS 803

Design Guide

Description

Conformity mark

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

Low Voltage Directive/Electromagnetic compatibility (EMC)

Country of use: Ukraine

089

Moroccan Declaration of Conformity (CMIM - Moroccan Conformity Mark)

Low Voltage Directive/Electromagnetic compatibility (EMC)

Country of use: Morocco

Eurasian Economic Union Declaration of Conformity (EAC - Eurasian Conformity Mark)

Customs Union Technical Regulations (CU TR)

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

tive (RoHS)

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

Certification of Compliance UL listed (UL - Underwriters Laboratories)

Safety organization

Countries of use: USA and Canada

Certification of Compliance UL recognized (UL - Underwriters Laboratories)

Safety organization

Countries of use: USA and Canada

NOTICE

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

CDS803P7K5T4E20H4XXCXXXSXXXXAXBXCXXXXDX

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

CDS803P30KT4E20H2XXXXXXS096XAXBXCXXXXDX

Introduction

VLT® Compressor Drive CDS 803

Design Guide

•

2 Safety

2.1 Safety Symbols

The following symbols are used in this manual:

DANGER

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE

Indicates information considered important, but not hazard-related (for example, messages relating to property damage).

2.2 Qualified Personnel

To allow trouble-free and safe operation of the unit, only qualified personnel with proven skills are allowed to transport, store, as-

semble, install, program, commission, maintain, and decommission this equipment.

Persons with proven skills:

Are qualified electrical engineers, or persons who have received training from qualified electrical engineers and are suitably

experienced to operate devices, systems, plant, and machinery in accordance with pertinent laws and regulations.

Are familiar with the basic regulations concerning health and safety/accident prevention.

Have read and understood the safety guidelines given in all manuals provided with the unit, especially the instructions given in

the Operating Guide.

Have good knowledge of the generic and specialist standards applicable to the specific application.

2.3 Safety Precautions

WARNING

HAZARDOUS VOLTAGE

AC drives contain hazardous voltage when connected to the AC mains or connected on the DC terminals. Failure to perform

installation, start-up, and maintenance by skilled personnel can result in death or serious injury.

Only skilled personnel must perform installation, start-up, and maintenance.

WARNING

UNINTENDED START

When the drive is connected to AC mains, DC supply, or load sharing, the motor may start at any time. Unintended start during

programming, service, or repair work can result in death, serious injury, or property damage. Start the motor with an external

switch, a fieldbus command, an input reference signal from the local control panel (LCP), via remote operation using MCT 10

software, or after a cleared fault condition.

Disconnect the drive from the mains.

Press [Off/Reset] on the LCP before programming parameters.

Ensure that the drive is fully wired and assembled when it is connected to AC mains, DC supply, or load sharing.

Safety

VLT® Compressor Drive CDS 803

Design Guide

WARNING

DISCHARGE TIME

The drive contains DC-link capacitors, which can remain charged even when the drive is not powered. High voltage can be

present even when the warning indicator lights are off.

Failure to wait the specified time after power has been removed before performing service or repair work could result in death or

serious injury.

Stop the motor.

Disconnect AC mains, permanent magnet type motors, and remote DC-link supplies, including battery back-ups, UPS, and

DC-link connections to other drives.

Wait for the capacitors to discharge fully. The minimum waiting time is specified in the table Discharge time and is also visible

on the nameplate on the top of the drive.

Before performing any service or repair work, use an appropriate voltage measuring device to make sure that the capacitors

are fully discharged.

Table 2: Discharge Time

Voltage [V]

Power range [kW (hp)]

Minimum waiting time (minutes)

3x200

6.0–10 (8.0–15)

3x400

6.0–7.5 (8.0–10)

3x400

10–30 (15–40)

WARNING

LEAKAGE CURRENT HAZARD

Leakage currents exceed 3.5 mA. Failure to ground the drive properly can result in death or serious injury.

Ensure that the minimum size of the ground conductor complies with the local safety regulations for high touch current

equipment.

WARNING

EQUIPMENT HAZARD

Contact with rotating shafts and electrical equipment can result in death or serious injury.

Ensure that only trained and qualified personnel perform installation, start-up, and maintenance.

Ensure that electrical work conforms to national and local electrical codes.

Follow the procedures in this manual.

CAUTION

INTERNAL FAILURE HAZARD

An internal failure in the drive can result in serious injury when the drive is not properly closed.

Ensure that all safety covers are in place and securely fastened before applying power.

Safety

VLT® Compressor Drive CDS 803

Design Guide

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