Danfoss VLT CDS 803 Bedienungsanleitung

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

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 mm2Cu 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. Supple-

mentary 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

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

1RFI 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 Quick Guide

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.

D

130BB614.10

130BC246.10

Enclosure Height [mm] Width [mm] Depth [mm] Mounting hole [mm] Max.

Weight

Frame IP Class A A1) 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.

Quick Guide Quick Guide

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.

UT1

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

Motor

UVW-DC+DC

MAINS

1Line

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

Quick Guide Quick Guide

-DC+DC

BR- BR+ U V W

M A I N S

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

U V W

130BT302.12

Illustration 1.4 H3-H5 Frame

130BA262.10

I N S

+DC

BR- BR+ UVW

RELAY 1 RELAY 2

Illustration 1.5 When mounting cables, first mount and tighten

ground cable.

130BA263.10

MAINS

+DC

BR- BR+ UVW

91 92 93

L1 L2 L3

RELAY 1 RELAY 2

Illustration 1.6 Mount mains plug and tighten wires.

Quick Guide Quick Guide

+DC

BR- BR+ UVW

MAINS

L1 L2 L3

91 92 93

RELAY 1 RELAY 2

- 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 short-

circuit 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 Arms (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

Quick Guide Quick Guide

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.

Com.

Warn.

Alarm

Hand

O

Reset Auto

Menu Status Quick

Menu Main

Min. 16 mm2

Equalizing cable

Control cables

All cable entries in

one side of panel

Earthing rail

Cable insula-

tion stripped

Output con-

tactor 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

Quick Guide Quick Guide

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