Danfoss VLT CDS 803 User manual

Operating Guide
VLT® Compressor Drive CDS 803
6–30 kW
vlt-drives.danfoss.com

1
1.1
1.2
1.2.1
1.2.2
1.3
1.4
1.5
1.6
2
2.1
2.2
2.3
3
3.1
3.1.1
3.1.2
3.1.2.1
3.1.2.2
3.2
3.2.1
3.2.1.1
3.2.2
3.2.2.1
3.2.3
3.2.3.1
3.2.3.2
3.2.3.3
3.2.3.4
3.2.3.5
3.2.3.6
3.2.4
3.2.5
4
4.1
Contents
Introduction 6
Purpose of this Operating Guide 6
Additional Resources 6
Supplementary Documentation 6
VLT® Motion Control Tool MCT 10 Software Support 6
Manual and Software Version 6
Approvals and Certifications 6
Disposal 7
CE Declaration 8
Safety 10
Safety Symbols 10
Qualified Personnel 10
Safety Precautions 10
Installation 12
Mechanical Installation 12
Side-by-side Installation 12
Operating Environment 12
Derating for Ambient Temperature and Switching Frequency 12
Derating for Low Air Pressure and High Altitudes 12
Electrical Installation 12
Electrical Installation in General 12
Fastener Torque Ratings 12
Fuses and Circuit Breakers 13
Recommendation of Fuses and Circuit Breakers 13
Electrical Wiring 14
Wiring Schematic 14
Terminal Overview of Enclosure Sizes H3–H5 15
Terminal Overview of Enclosure Size H6 16
Connecting to Mains and Compressor Terminals 16
Relay Terminals 17
Control Terminals 18
Setting Up RS485 Serial Communication 19
EMC-compliant Electrical Installation 20
Commissioning 24
Programming Interfaces 24
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Contents
VLT® Compressor Drive CDS 803
Operating Guide

4.2
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
4.2.5.1
4.2.5.2
4.3
5
5.1
5.2
6
6.1
6.1.1
6.1.2
6.2
6.3
6.4
6.4.1
6.4.2
6.4.3
6.4.4
6.4.5
6.4.6
6.4.7
6.4.8
6.4.9
6.5
6.6
6.7
6.8
6.9
6.10
7
7.1
Local Control Panel (LCP) 24
Programming via the Quick Menu 25
Programming via the Main Menu 25
Data Transfer from Drive to LCP 26
Data Transfer from LCP to Drive 26
Restoring Factory Default Settings 26
Recommended Initialization (via Parameter 14-22 Operation Mode) 26
Two-finger Initialization 27
Starting Up the Drive for the First Time 27
Troubleshooting 28
Acoustic Noise or Vibration 28
Warnings and Alarms 28
Specifications 32
Electrical Data 32
Electrical Data 3x200–240 V AC 32
Electrical Data 3x380–480 V AC 32
Mains Supply (L1, L2, L3) 33
Compressor Output (U, V, W) 33
Control Input/Output 34
10 V DC Output 34
24 V DC Output 34
Analog Inputs 34
Analog Outputs 34
Digital Inputs 34
Digital Outputs 35
Relay Outputs, Enclosure Sizes H3–H5 35
Relay Outputs, Enclosure Size H6 35
RS485 Serial Communication 36
Ambient Conditions 36
Conforming Standards 37
Cable Lengths and Cross-sections 37
Acoustic Noise 37
Shipping Dimensions 38
Accessories and Spare Parts 38
Appendix 39
Abbreviations 39
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Contents
VLT® Compressor Drive CDS 803
Operating Guide

7.2 Conventions 40
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VLT® Compressor Drive CDS 803
Operating Guide

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1 Introduction
1.1 Purpose of this Operating Guide
This Operating Guide provides information for safe installation and commissioning of the AC drive. It is intended for use by qualified
personnel.
Read and follow the instructions to use the drive safely and professionally.
Pay particular attention to the safety instructions and general warnings. Always keep this Operating Guide with the drive.
VLT®is a registered trademark for Danfoss A/S.
1.2 Additional Resources
1.2.1 Supplementary Documentation
Other resources are available to understand advanced drive functions and programming.
The Programming Guide provides information on how to program and includes complete parameter descriptions.
The Design Guide provides detailed information about capabilities and functionality to design motor control systems.
The Modbus RTU Operating Instructions explains how to physically establish and configure communication between the Danfoss
FC Series and a controller using the Modbus RTU protocol. Download the Operating Instructions from www.danfoss.com in the
section Service and Support/Documentation.
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
AQ321748767627, version 0301
Various editorial updates.
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
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Introduction
VLT® Compressor Drive CDS 803
Operating 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
1.5 Disposal
Do not dispose of equipment containing electrical components together with domestic waste.
Collect it separately in accordance with local and currently valid legislation.
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Introduction
VLT® Compressor Drive CDS 803
Operating Guide

1.6 CE Declaration
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Introduction
VLT® Compressor Drive CDS 803
Operating Guide

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Introduction
VLT® Compressor Drive CDS 803
Operating Guide

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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.
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Operating Guide

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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)
15
3x400
6.0–7.5 (8.0–10)
4
3x400
10–30 (15–40)
15
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.
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VLT® Compressor Drive CDS 803
Operating Guide

3 Installation
3.1 Mechanical Installation
3.1.1 Side-by-side Installation
The drive can be mounted side by side but requires the clearance specified in Table 3 above and below for cooling.
Table 3: Clearance Required for Cooling
Power [kW (hp)]
Clearance above/below [mm (in)]
Size
IP protection rating
3x200–240 V
3x380–480 V
H3
IP20
–
6.0–7.5 (8.0–10)
100 (4)
H4
IP20
6.0–7.5 (8.0–10)
10 (15)
100 (4)
H5
IP20
10 (15)
18.5–22 (25–30)
100 (4)
H6
IP20
–
30(40)
200 (7.9)
NOTICE
With IP21/NEMA Type1 option kit mounted, a distance of 50 mm (2 in) between the units is required.
3.1.2 Operating Environment
3.1.2.1 Derating for Ambient Temperature and Switching Frequency
Ensure that the ambient temperature measured over 24 hours is at least 5 °C (9 °F) lower than the maximum ambient temperature
that is specified for the drive. If the drive is operated at a high ambient temperature, decrease the constant output current. For
derating specifications, see the VLT® Compressor Drive CDS 803 Design Guide listed in 1.2 Additional Resources.
3.1.2.2 Derating for Low Air Pressure and High Altitudes
The cooling capability of air is decreased at low air pressure. For altitudes above 2000 m (6562 ft), contact Danfoss regarding PELV.
Below 1000 m (3281 ft) altitude, derating is not necessary. For altitudes above 1000 m (3281 ft), decrease the ambient temperature
or the maximum output current. Decrease the output by 1% per 100 m (328 ft) altitude above 1000 m (3281 ft) or reduce the maxi-
mum ambient cooling air temperature by 1 °C (1.8 °F) per 200 m (656 ft).
3.2 Electrical Installation
3.2.1 Electrical Installation in General
All cabling must comply with national and local regulations on cable cross-sections and ambient temperature. Copper conductors
are required. 75 °C (167 °F) is recommended.
3.2.1.1 Fastener Torque Ratings
Table 4: Tightening Torques for Enclosure Sizes H3–H6, 3x200–240 V & 3x380–480 V
Power [kW (hp)]
Torque [Nm (in-lb)]
Enclo-
sure size
IP protec-
tion rat-
ing
3x200–240 V
3x380–480 V
Mains
Motor
DC connec-
tion
Control ter-
minals
Ground
Relay
H3
IP20
–
6.0–7.5 (8.0–10)
0.8 (7)
0.8 (7)
0.8 (7)
0.5 (4)
0.8 (7)
0.5 (4)
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Operating Guide

Power [kW (hp)]
Torque [Nm (in-lb)]
H4
IP20
6.0–7.5 (8.0–
10)
10–15 (15–20)
1.2 (11)
1.2 (11)
1.2 (11)
0.5 (4)
0.8 (7)
0.5 (4)
H5
IP20
10 (15)
18.5–22 (25–30)
1.2 (11)
1.2 (11)
1.2 (11)
0.5 (4)
0.8 (7)
0.5 (4)
H6
IP20
–
30 (40)
4.5 (40)
4.5 (40)
–
0.5 (4)
3 (27)
0.5 (4)
3.2.2 Fuses and Circuit Breakers
Fuses and circuit breakers ensure that possible damage to the drive is limited to damage inside the unit. Danfoss recommends fuses
on the supply side as protection. For further information, see the application note Fuses and Circuit Breakers found on www.dan-
foss.com under Service and support/Documentation/Manuals & guides.
NOTICE
Use of fuses on the supply side is mandatory for IEC 60364 (CE) and NEC 2009 (UL) compliant installations.
3.2.2.1 Recommendation of Fuses and Circuit Breakers
Table 5: Fuses and Circuit Breakers
Circuit breakers(1)
Fuse
UL
Non-UL
UL
Non-UL
Bussmann
Bussmann
Bussmann
Bussmann
Maximum fuse
Power [kW (hp)]
Type RK5
Type RK1
Type J
Type T
Type gG
3x200–240 V
6.0 (8.0)
–
–
FRS-R-50
KTN-R50
JKS-50
JJN-50
gG-50
7.5 (10)
FRS-R-50
KTN-R50
JKS-50
JJN-50
gG-50
10 (15)
FRS-R-80
KTN-R80
JKS-80
JJN-80
gG-63
3x380–480 V
6.0 (8.0)
–
–
FRS-R-25
KTS-R25
JKS-25
JJS-25
gG-25
7.5 (10)
FRS-R-25
KTS-R25
JKS-25
JJS-25
gG-25
10 (15)
FRS-R-50
KTS-R50
JKS-50
JJS-50
gG-50
18.5 (25)
–
–
–
JJS-80
gG-63
22 (30)
JJS-80
gG-63
30 (40)
JJS-125
gG-80
1Circuit breakers have not been evaluated by Danfoss as part of the certification process.
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3.2.3 Electrical Wiring
3.2.3.1 Wiring Schematic
L1
L2
L3
3-phase
power
input
PE
PE
+10 V DC
0-10 V DC-
0-10 V DC-
50 (+10 V OUT)
54 (A IN)
53 (A IN)
55 (COM A IN/OUT)
0/4-20 mA
0/4-20 mA
42 0/4-20 mA A OUT / D OUT
45 0/4-20 mA A OUT / D OUT
18 (D IN)
19 (D IN)
27 (D IN)
29 (
D IN)
12 (+24 V OUT)
24 V (NPN)
20 (COM D IN)
O V (PNP)
24 V (NPN)
O V (PNP)
24 V (NPN)
O V (PNP)
24 V (NPN)
O V (PNP)
Bus ter.
Bus ter.
RS485
Interface RS485
(N RS485) 69
(P RS485) 68
(Com RS485 ) 61
(PNP)-Source
(NPN)-Sink
ON=Terminated
OFF=Unterminated
ON
1 2
240 V AC 3 A
Not present on all power sizes
Do not connect shield to 61
01
02
03
relay 1
relay 2
UDC+
UDC-
Motor
U
V
W
e30bj246.10
06
05
04
240 V AC 3 A
Illustration 1: Basic Wiring Schematic Drawing
NOTICE
There is no access to UDC- and UDC+ on the following units:
IP20, 380–480 V, 30 kW (40 hp).
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VLT® Compressor Drive CDS 803
Operating Guide

3.2.3.2 Terminal Overview of Enclosure Sizes H3–H5
1
2
2
3
4
U
V
W -DC
+DC
e30bb634.11
5
MAINS
MOTOR
Illustration 2: Enclosure Sizes H3–H5
1
Mains
2
Ground
3
Compressor
4
Relays
5
Control terminals
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VLT® Compressor Drive CDS 803
Operating Guide

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1.
3.2.3.3 Terminal Overview of Enclosure Size H6
1
95
99
L1 91 / L2 92 / L3 93
U 96 /
V 97 /
W 98
03 02 01
06 05 04
2 3 4
e30bb762.12
Illustration 3: Enclosure Size H6
1
Mains
2
Ground
3
Compressor
4
Relays
3.2.3.4 Connecting to Mains and Compressor Terminals
Tighten all terminals in accordance with the information provided in 3.2.1.1 Fastener Torque Ratings.
Keep the compressor cable as short as possible to reduce the noise level and leakage currents.
Use a shielded/armored compressor cable to comply with the EMC emission specifications and connect this cable to both the
decoupling plate and the compressor. Also see 3.2.5 EMC-compliant Electrical Installation.
Connect the ground cable to the ground terminal, then connect the mains supply to terminals L1, L2, and L3.
e30bi968.10
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VLT® Compressor Drive CDS 803
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Connect the ground cable to the ground terminal, then connect the compressor to terminals U, V, and W.
e30bi967.10
Table 6: Connection of Compressor to Terminals
Drive terminals
Compressor
U
T1
V
T2
W
T3
3.2.3.5 Relay Terminals
Relay 1
Terminal 01: Common.
Terminal 02: Normally open.
Terminal 03: Normally closed.
Relay 2
Terminal 04: Common.
Terminal 05: Normally open.
Terminal 06: Normally closed.
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Relay1
Relay2
03
02
01
06
05
04
e30bi798.10
Illustration 4: Relay Outputs 1 and 2
3.2.3.6 Control Terminals
Remove the terminal cover to access the control terminals.
Use a flat-edged screwdriver to push down the lock lever of the terminal cover under the LCP, then remove the terminal cover as
shown in the following illustration.
e30bd331.11
Illustration 5: Removing the Terminal Cover
The following illustration shows all the drive control terminals. Applying start (terminal 18), connection between terminals 12-27,
and an analog reference (terminal 53 or 54, and 55) make the drive run.
The digital input mode of terminal 18, 19, 27, and 29 is set in parameter 5-00 Digital Input Mode (PNP is default value).
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e30bf892.10
12 20 55
18 19 27 29 42 54
45 50 53
DIGI IN
61 68 69
N P COMM. GND
+24 V
GND GND
10 V OUT 10 V/20 mA IN 0/4-20 mA A OUT/DIG OUT
BUS TER.
OFF ON
DIGI IN DIGI IN DIGI IN 0/4-20 mA A OUT/DIG OUT 10 V/20 mA IN
Illustration 6: Control Terminals
3.2.4 Setting Up RS485 Serial Communication
3.2.4.1 RS485 Features
RS485 is a 2-wire bus interface compatible with multi-drop network topology. This interface contains the following features:
Ability to select from the following communication protocols:
FC (default protocol)
Modbus RTU
Functions can be programmed remotely using the RS485 connection or in parameter group 8-** Communications and Options.
A switch (BUS TER) is provided on the control card for bus termination resistance.
NOTICE
Altering between the supported communication protocols can be accessed and changed via the LCP as parameter 8-30 Protocol is
not available in VLT® Motion Control Tool MCT 10.
3.2.4.2 Configuring RS485 Serial Communication
Procedure
Connect RS485 serial communication wiring to terminals (P RS485) 68 and (N RS485) 69.
Use shielded serial communication cable.
Properly ground the wiring. Refer to 3.2.5 EMC-compliant Electrical Installation.
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•
•
•
•
•
•
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-
-
Configure all required settings such as address, baud rate, and so on in parameter group 8-** Communications and Options.
For more details on parameters, refer to VLT® Compressor Drive CDS 803 Programming Guide listed in 1.2 Additional Re-
sources.
Example
+
e30bi768.10
RS485
69
GND
68
Illustration 7: RS485 Wiring Connection
3.2.5 EMC-compliant Electrical Installation
To obtain an EMC-compliant installation, be sure to follow all electrical installation instructions. Also, remember to practice the fol-
lowing:
When using relays, control cables, a signal interface, fieldbus, or brake, connect the shield to the enclosure at both ends. If the
ground path has high impedance, is noisy, or is carrying current, break the shield connection on 1 end to avoid ground current
loops.
Convey the currents back to the unit using a metal mounting plate. Ensure good electrical contact from the mounting plate by
securely fastening the mounting screws to the drive chassis.
Use shielded cables for motor output cables. An alternative is unshielded motor cables within metal conduit.
Ensure that motor and brake cables are as short as possible to reduce the interference level from the entire system.
Avoid placing cables with a sensitive signal level alongside motor and brake cables.
For communication and command/control lines, follow the particular communication protocol standards. For example, USB
must use shielded cables, but RS485/ethernet can use shielded UTP or unshielded UTP cables.
Ensure that all control terminal connections are rated protective extra low voltage (PELV).
NOTICE
TWISTED SHIELD ENDS (PIGTAILS)
Twisted shield ends increase shield impedance at higher frequencies, which increases the leakage current.
Use integrated shield clamps instead of twisted shield ends.
NOTICE
SHIELDED CABLES
If shielded cables or metal conduits are not used, the unit and the installation do not meet regulatory limits on radio frequency
(RF) emission levels.
NOTICE
EMC INTERFERENCE
Failure to isolate power, motor, and control cables can result in unintended behavior or reduced performance.
Use shielded cables for motor and control wiring.
Provide a minimum 200 mm (7.9 in) separation between mains input, motor cables, and control cables.
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VLT® Compressor Drive CDS 803
Operating Guide