Danfoss VLT CDS 803 User Manual Download

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Design Guide

VLT® Compressor Drive CDS 803

6–30 kW

vlt-drives.danfoss.com

Summary of Contents for VLT CDS 803

Page 1: ...Design Guide VLT Compressor Drive CDS 803 6 30 kW vlt drives danfoss com...

Page 2: ......

Page 3: ...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...

Page 4: ...mperature 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 Los...

Page 5: ...t 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 Dera...

Page 6: ...patibility 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 R...

Page 7: ...ary 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 softw...

Page 8: ...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 Countr...

Page 9: ...erstood 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 applicabl...

Page 10: ...ge 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 W A R N I N G LEAKAGE CURRENT HAZARD Leakage currents exceed 3 5 mA Failure to gr...

Page 11: ...rent 2 analog outputs 2 relay outputs RS485 serial communication Danfoss FC protocol and VLT Motion Control Tool MCT 10 support Modbus RTU The drive is a free standing wall mountable or cabinet mounta...

Page 12: ...functions are programmed in the drive for enhanced system performance The functions require minimum pro gramming or setup For activation of the functions refer to the VLT Compressor Drive CDS 803 Pro...

Page 13: ...missing or low lubrication the VLT Compressor Drive CDS 803 protects the compressor if the speed drops below the minimum speed detection limit for too long In case of excessive low speed the drive is...

Page 14: ...play if there is a start signal and the INTERVAL BETWEEN STARTS has not expired Warning 97 Stop Delay is shown in the display if there is a stop signal and the MINIMUM RUNTIME has not expired e30bj250...

Page 15: ...ed limit Decrease ORM timer Increase ORM timer Increase ORM timer ORM low speed running time expire ORM timer reset ORM low speed running time starts Time Illustration 7 Oil Return Management 3 2 1 6...

Page 16: ...ce 3 2 2 1 Automatic Motor Adaptation AMA Automatic motor adaptation AMA is an automated test procedure used to measure the electrical characteristics of the motor AMA provides an accurate electronic...

Page 17: ...e flow temperature or other system requirements must be maintained The drive can use 2 feedback signals from 2 different devices allowing the system to be regulated with different feedback require men...

Page 18: ...or Par 13 43 Logic Rule Operator 2 Par 13 51 SL Controller Event Par 13 52 SL Controller Action e30bb671 13 Coast Start timer Set Do X low Select set up 2 Running Warning Torque limit Digital input X...

Page 19: ...13 44 Logic Rule Boolean 3 e30bb673 10 Illustration 12 Logic Rules 3 3 VLT Compressor Drive CDS 803 Protections The drive has a range of built in protection functions to protect itself and the compres...

Page 20: ...de the drive 1st fault Mains side fuses are mandatory for UL com pliance N O T I C E To ensure compliance with IEC 60364 for CE or NEC 2017 for UL it is mandatory to use fuses and or circuit breakers...

Page 21: ...nstant output frequency from the drive that is the load generates energy During deceleration ramp down if the moment inertia is high the friction is low and the ramp down time is too short for the ene...

Page 22: ...ns It is now possible to determine the total losses of a system for the 8 operating points defined in the standard including the part load operation via a simple addition of power losses Danfoss helps...

Page 23: ...r IZ which is the voltage drop due to impedance at the rated current expressed as a percent of rated voltage The most common line reactors have either 3 or 5 impedance When to use line reactors It is...

Page 24: ...leg grounded delta the RFI filter must be turned off In the OFF position the internal capacitors between the chassis ground the input RFI filter and the DC link are cut off As the RFI switch is turne...

Page 25: ...s are placed between the drive and the motor They are nanocrystaline cores that mitigate high frequency noise in the motor cable shielded or unshielded and eliminate bearing currents and hence Electro...

Page 26: ...losses the longer the cables the more resistance In general when correctly selected the losses in cables shorter than 25 m 82 ft can be neglected In single wire cables with individual shielding curre...

Page 27: ...ht enclosure protection IP20 kg lb 7 9 17 4 7 9 17 4 9 5 22 9 Efficiency best case typical 2 97 3 97 1 98 5 97 1 97 2 97 1 1 Applies to dimensioning of drive cooling If the switching frequency is high...

Page 28: ...24 5 54 Efficiency best case typical 2 98 4 98 98 2 97 8 98 1 97 9 98 1 97 9 98 1 97 9 97 8 1 Applies to dimensioning of drive cooling If the switching frequency is higher than the default setting th...

Page 29: ...Ri Approximately 10 k Maximum voltage 20 V Current level 0 4 20 mA scalable Input resistance Ri 500 Maximum current 29 mA Resolution on analog input 10 bit The analog inputs are galvanically isolated...

Page 30: ...um terminal load AC 1 1 on 01 02 04 05 NO Resistive load 250 V AC 3 A Maximum terminal load AC 15 1 on 01 02 04 05 NO Induc tive load cos 0 4 250 V AC 0 2 A Maximum terminal load DC 1 1 on 01 02 04 05...

Page 31: ...RS485 Serial Communication Terminal number 68 P TX RX 69 N TX RX Terminal number 61 common for terminals 68 and 69 The RS485 serial communication outputs are galvanically isolated from the supply vol...

Page 32: ...XBXCXXXXDX The VLT Compressor Drive CDS 803 with S096 in the type code is certified against UL EN IEC 60730 1 Example CDS803P30KT4E20H2XXXXXXS096XAXBXCXXXXDX 4 7 Cable Lengths and Cross sections Maxim...

Page 33: ...Enclosure Size H3 H4 H5 H6 IP class IP20 IP20 IP20 IP20 Power kW hp 3x200 240 V 6 0 7 5 8 0 10 10 15 3x380 480 V 6 0 7 5 8 0 10 10 15 18 5 22 25 30 30 40 Height mm in A 255 10 0 296 11 7 334 13 1 518...

Page 34: ...4 H5 10 15 18 5 22 25 30 IP20 9 5 20 9 395 15 6 233 9 2 380 15 H6 30 40 IP20 24 5 54 0 850 33 5 370 15 6 460 18 1 4 10 dU dt Table 9 dU dt Data Cable length m ft AC line voltage V Rise time sec V pea...

Page 35: ...376 0 92 1 957 50 164 400 0 536 0 97 1 448 100 328 400 0 696 0 95 1 092 150 492 400 0 8 0 965 0 965 10 33 480 0 384 1 2 2 5 50 164 480 0 632 1 18 1 494 100 328 480 0 712 1 2 1 348 150 492 480 0 832 1...

Page 36: ...age and do not have voltage applied maintenance of the capacitors in the drive may be required To avoid damage to the internal DC link capacitors reforming is required if the drive has been stored wit...

Page 37: ...ance of 50 mm 2 in between the units is required 5 3 Operating Environment In environments with airborne liquids particles or corrosive gases ensure that the IP Type rating of the equipment matches th...

Page 38: ...Mean value Maximum value 1 Mean value Maximum value 1 Sea salt n a None Salt mist Salt mist Sulfur oxide mg m3 0 1 0 3 1 0 5 0 10 Hydrogen sulfide mg m3 0 01 0 1 0 5 3 0 10 Chlorine mg m3 0 01 0 1 0 3...

Page 39: ...alls or floors 5 3 5 Derating for Ambient Temperature and Switching Frequency Ensure that the ambient temperature measured over 24 h is at least 5 C 9 F lower than the maximum ambient temperature that...

Page 40: ...g frequency of 5 0 kHz f_sw If the switching frequency is increased the following derating curves apply e30bi924 10 0 10 20 30 40 50 60 70 80 90 100 110 0 2 5 10 16 52 C 45 C 40 C Iout fsw kHz Illustr...

Page 41: ...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 5 4 IP21 NEMA Type 1 Enclosure Kit If environment air quality...

Page 42: ...e30bb902 12 A B C Illustration 25 H3 H6 AJ330233902305en 000201 130R0596 42 Danfoss A S 2021 05 Mechanical Installation Considerations VLT Compressor Drive CDS 803 Design Guide...

Page 43: ...void resonance problems within the system Upper and lower frequency limits Parameter group 4 6 Speed Bypass Switching pattern and switching frequency parameter group 14 0 Inverter Switching 5 6 Recomm...

Page 44: ...red in accordance with Danfoss company guidelines on prohibited and restricted substances A list of these substances is available at www danfoss com This symbol on the product indicates that it may no...

Page 45: ...o 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...

Page 46: ...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...

Page 47: ...erview of Enclosure Sizes H3 H5 1 2 2 3 4 U V W DC DC e30bb634 11 5 MAINS MOTOR Illustration 28 Enclosure Sizes H3 H5 1 Mains 2 Ground 3 Compressor 4 Relays 5 Control terminals AJ330233902305en 000201...

Page 48: ...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 t...

Page 49: ...urrents according to IEC 61800 3 If optimum EMC performance is required avoid exceeding overvoltage limits within the DC bus by making sure that the energy charged into the DC link through the RFI fil...

Page 50: ...rminal 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 illus...

Page 51: ...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...

Page 52: ...drive system in the range 30 MHz to 1 GHz is generated from the inverter motor cable and the motor Capacitive currents in the motor cable coupled with a high dU dt from the motor voltage generate lea...

Page 53: ...s and light industries EN IEC 61800 3 Category C3 Second environ ment Industrial Category C2 First environment Home and office Category C1 First environ ment Home and office Category C3 Second envi ro...

Page 54: ...ctional unit for an end user and intended to be installed and operated together to perform a specific task The EMC Directive applies to products systems and installations but in case the installation...

Page 55: ...low product standard IEC 61800 3 See Table 20 Table 20 EMC Immunity Voltage Range 200 240 V 380 480 V Basic standard Burst IEC 61000 4 4 Surge IEC 61000 4 5 ESD IEC 61000 4 2 Radiated electro magnetic...

Page 56: ...s product can cause radio interference in which case supplementary mitigation measures may be required PELV and galvanic isolation compliance All control and relay terminals comply with PELV excluding...

Page 57: ...rotective extra low voltage PELV N O T I C E TWISTED SHIELD ENDS PIGTAILS Twisted shield ends increase the shield impedance at higher frequencies which reduces the shield effect and increases the leak...

Page 58: ...10 9 4 11 13 4 4 6 15 90 DC BR B M AIN S L1 L2 L3 91 92 93 RELA Y 1 RELA Y 2 99 LC UV W MOTOR Illustration 36 Example of Proper EMC Installation AJ330233902305en 000201 130R0596 58 Danfoss A S 2021 05...

Page 59: ...iation of electric noise depends on the transfer impedance ZT The shield of a cable is normally designed to reduce the transfer of electric noise However a shield with a lower transfer impedance ZT va...

Page 60: ...l cable Minimum cable cross section 16 mm2 6 AWG 1 2 PE FC PE PLC e30bb922 12 PE PE 10 mm Illustration 38 Shielding Clamps at Both Ends 1 Minimum 16 mm2 6 AWG 2 Equalizing cable 6 5 7 1 50 60 Hz Groun...

Page 61: ...inusoidal current from mains which increases the input current IRMS A non sinusoidal current is trans formed with a Fourier analysis and split into sine wave currents with different frequencies that i...

Page 62: ...1 3 hp total power 2 IEC EN 61000 3 12 Equipment 16 75 A and professional equipment as from 1 kW 1 3 hp up to 16 A phase current 6 6 2 Harmonics Test Results Emission Power sizes up to 10 kW 15 hp 20...

Page 63: ...ey may be used as the basis for calculation of the harmonic currents influence on the power supply system and for the documentation of compliance with relevant regional guide lines IEEE 519 1992 G5 4...

Page 64: ...d Power Size on Leakage Current Power Size a Power Size B The leakage current also depends on the line distortion e30bb956 12 THDv 0 THDv 5 Leakage current Illustration 45 Influence of Line Distortion...

Page 65: ...e correct grounding of the equipment by a certified electrical installer 6 8 1 Using a Residual Current Device RCD Where residual current devices RCDs also known as earth leakage circuit breakers ELCB...

Page 66: ...of direct or indirect contact only an RCD of Type B is allowed on the supply side of this product Otherwise apply another protective measure such as separation from the environment by double or reinf...

Page 67: ...7 2 Type Code Description Table 26 Type Code Descriptions Position Description Options 01 06 Product group CDS 803 07 10 Power rating 6 0 30 kW 8 0 40 hp 11 Number of phases 3 11 12 Mains voltage T2...

Page 68: ...nclosure size H6 132B0217 Decoupling plates Decoupling plate enclosure size H3 120Z0582 Decoupling plate enclosure sizes H4 and H5 120Z0583 Decoupling plate enclosure size H6 120Z0837 Table 28 Descrip...

Page 69: ...cond Nm Newton meter PM N Nominal motor power PCB Printed circuit board PELV Protective extra low voltage RPM Revolutions per minute RPS Revolutions per second s Second UM N Nominal motor voltage V Vo...

Page 70: ...er group name Alarms warnings All dimensions in drawings are in metric values imperial values in brackets An asterisk indicates the default setting of a parameter AJ330233902305en 000201 130R0596 70 D...

Page 71: ...27 Electrical installation 45 Electromagnetic compatibility 52 See EMC Electronic thermal overvoltage 17 EMC General aspects 52 Compatibility 56 Use of EMC compliant cables 59 Emission requirements 5...

Page 72: ...ons 34 Shock 39 Side by side installation 37 SLC 18 Smart logic control 18 Standards EN 50598 2 27 28 EN 60664 1 28 IEC 60721 3 3 31 IEC 60068 2 43 H2S 31 UL Safety standards 32 EMC standards emission...

Page 73: ...he serial communication port FC port C Control command Functions are divided into 2 groups Functions in group 1 have higher priority than functions in group 2 Group 1 Reset coast stop reset and coast...

Page 74: ...ains the required speed pressure temperature and so on by adjusting the output frequency to match the varying load PM N Rated motor power nameplate data in kW or hp Power factor The power factor is th...

Page 75: ...the drive is subject to an overtemperature or when the drive is protecting the compressor process or mechanism The drive prevents a restart until the cause of the fault has disappeared To cancel the...

Page 76: ...rinted material Danfoss reserves the right to alter its products without notice This also applies to products already on order provided that such alterations can be made without subsequential changes...

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