Danfoss VLT CDS 803 User manual

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 3

1.2.1 Available Literature 3

1.2.2 Approvals 3

1.2.3 IT Line Power 3

1.2.4 Avoid Unintended Start 3

1.2.5 Disposal Instruction 3

1.3 Installation 4

1.3.1 Before Starting Repair Work 4

1.3.2 Enclosure Types 4

1.3.3 Side-by-Side Installation 4

1.3.4 Dimensions 5

1.3.6 Connecting to Line Power and Compressor 6

1.3.7 Fuses 8

1.3.8 EMC-compatible Electrical Installation 9

1.3.9 Control Terminals 10

1.4 Programming 12

1.4.2 The Start-up Wizard 13

1.4.3 Main Menu Structure 23

1.5 Acoustic Noise or Vibration 25

1.6 Warnings and Alarms 25

1.7 General Specifications 26

1.7.1 Line Power Supply 3x200–240 V AC 26

1.7.2 Line Power Supply 3x380–480 V AC 27

1.8 Special Conditions 31

1.8.1 Derating for Ambient Temperature and Switching Frequency 31

1.8.2 Derating for Low Air Pressure 31

1.9 Options for VLT®Compressor Drive CDS 803 31

Contents Quick Guide

1 Quick Guide

1.1 Safety

1.1.1 Warnings

WARNING

High Voltage Warning

The voltage of the adjustable frequency drive is

dangerous whenever it is connected to line power.

Incorrect installation of the compressor or adjustable

frequency drive 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!

Adjustable frequency drives contain DC link capacitors

that can remain charged even when the adjustable

frequency drive is not powered. To avoid electrical

hazards, disconnect AC line power, any permanent

magnet type compressors, and any remote DC link

power supplies, including battery backups, UPS, and DC

link connections to other adjustable frequency drives.

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 for

the specified period of time after power has been

removed to do 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 adjustable

frequency drive exceeds 3.5 mA. cross-sectionAccording

to IEC 61800-5-1, a reinforced protective ground

connection must be ensured with a min. 10 mm2 Cu or

an additional PE wire - with the same cable cross-section

as the line power 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 grounding of the adjustable frequency drive

and the use of RCDs must always follow national and

local regulations.

WARNING

Installation at High Altitudes

For altitudes above 6,600 feet [2 km], contact Danfoss

regarding PELV.

1.1.2 Safety Instructions

•Make sure the adjustable frequency drive is

properly connected to ground.

•Do not remove AC line input connections,

compressor connections or other power

connections while the adjustable frequency drive

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 adjustable frequency drive

from line power.

Quick Guide Quick Guide

1.2 Introduction

1.2.1 Available Literature

This Quick Guide contains basic information necessary for

installing and running the adjustable frequency drive.

Supplementary publications and manuals are available

from Danfoss. See www.danfoss.com/BusinessAreas/DrivesSo-

lutions/ Documentations/VLT+Technical+Documentation.htm

for listings.

1.2.2 Approvals

Certification IP20

EC Declaration of

Conformity ✓

UL-listed ✓

C-tick ✓

Table 1.2 Approvals

The adjustable frequency drive complies with UL508C

thermal memory retention requirements. For more

information, refer to the section Motor Thermal Protection

in the Design Guide.

1.2.3 IT Line Power

CAUTION

IT Line Power

Installation on isolated line power source, that is, IT line

power.

Max. supply voltage allowed when connected to line

power: 440 V (3x380–480 V units).

Open the RFI switch by removing the screw on the side of

the adjustable frequency drive when at IT grid.

130BB612.10

1RFI switch

Figure 1.1 IP20

CAUTION

If reinserted, only use M3x12 screws.

1.2.4 Avoid Unintended Start

While the adjustable frequency drive is connected to line

power, the compressor can be started/stopped using

digital commands, bus commands, references or via the

LCP.

•Disconnect the adjustable frequency drive from

line power whenever personal safety consider-

ations 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

may 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.

Quick Guide Quick Guide

1.3 Installation

1.3.1 Before Starting Repair Work

1. Disconnect from line power (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

1.3.3 Side-by-Side Installation

The adjustable frequency drive 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

2 in [50 mm] between the units is required.

Quick Guide Quick Guide

1.3.4 Dimensions

NOTICE!

The figure in Table 1.6 is with LCP but all dimensions are the same without LCP.

D

130BB614.10

130BC246.10

Enclosure Height (in [mm]) Width (in [mm]) Depth (in

[mm])

Mounting hole (in [mm]) Max.

Weight

Frame IP Class A A1) a B b C d e f lb [kg]

H3 IP20 10 [255] 13 [329] 9.5 [240] 3.9 [100] 2.9 [74] 8.1 [206] 0.4

[11]

0.2 [5.5] 0.3

[8.1]

9.9 [4.5]

H4 IP20 11.7 [296] 14.1 [359] 10.8 [275] 5.3 [135] 4.1 [105] 9.5 [241] 0.5

[12.6]

0.3 [7] 0.33

[8.4]

17.4 [7.9]

H5 IP20 13.2 [334] 15.8 [402] 12.4 [314] 5.9 [150] 4.7 [120] 10 [255] 0.5

[12.6]

0.3 [7] 0.34

[8.5]

21 [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.

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, (167 °F [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

Quick Guide Quick Guide

1.3.6 Connecting to Line Power and

Compressor

The adjustable frequency drive is designed to operate

Danfoss VZH Compressors. For the 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-compatible 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 line power supply to terminals L1, L2 and

L3 and tighten.

130BB634.10

Motor

UVW-DC+DC

MAINS

1 Line

2 Ground

3 Compressor

4 Relays

Figure 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

Figure 1.3 Mount the two screws in the mounting plate, slide

it into place and tighten fully

MOTOR

U V W

130BT302.12

Figure 1.4 H3-H5 Frame

130BA262.10

I N S

+DC

BR- BR+ UVW

RELAY 1 RELAY 2

Figure 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

Figure 1.6 Mount line power 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

Figure 1.7 Tighten support bracket on line power 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 the DC link. The adjustable frequency drive 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 adjustable

frequency drive.

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

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