Danfoss VLT CDS 803 Guía

MAKING MODERN LIVING POSSIBLE

Design Guide

VLT®Compressor Drive CDS 803

vlt-drives.danfoss.com

Contents

1 Introduction 5

1.1 Purpose of the Manual 5

1.2 Document and Software Version 5

1.3 Safety Symbols 5

1.4 Abbreviations 5

1.5 Additional Resources 6

1.6 Denitions 6

1.7 Power Factor 8

2 Product Overview 9

2.1 Safety 9

2.2 CE Labelling 10

2.3 Air Humidity 11

2.4 Aggressive Environments 11

2.5 Vibration and Shock 12

2.6 Control Structures 12

2.6.1 Control Structure Open Loop 12

2.6.2 Local (Hand On) and Remote (Auto On) Control 12

2.6.3 Control Structure Closed Loop 13

2.6.4 Feedback Conversion 13

2.6.5 Reference Handling 14

2.6.6 Closed-loop Set-up Quick Guide 15

2.6.7 Tuning the Drive Closed-loop Controller 18

2.6.8 Manual PI Adjustment 18

2.7 General Aspects of EMC 19

2.7.1 General Aspects of EMC Emissions 19

2.7.2 Emission Requirements 20

2.7.3 EMC Test Results 21

2.8 Harmonics 21

2.8.1 Overview of Harmonics Emission 21

2.8.2 Harmonics Emission Requirements 21

2.8.3 Harmonics Test Results (Emission) 22

2.8.4 Immunity Requirements 22

2.9 Galvanic Isolation (PELV) 22

2.10 Ground Leakage Current 23

2.11 Extreme Running Conditions 23

3 Selection 24

3.1 Options and Accessories 24

3.1.1 Local Control Panel (LCP) 24

Contents Design Guide

3.1.2 Mounting of LCP in Panel Front 24

3.1.3 IP21/TYPE 1 Enclosure Kit 25

3.1.4 Decoupling Plate 26

4 How to Order 27

4.1 Conguration 27

4.2 Ordering Numbers 28

5 How to Install 29

5.1 Mechanical Dimensions 29

5.1.1 Dimensions 29

5.1.2 Shipping Dimensions 29

5.1.3 Side-by-side Installation 30

5.2 Electrical Data 31

5.2.1 Electrical Overview 31

5.2.2 Electrical Installation in General 32

5.2.3 Connecting to Mains and Compressor 32

5.2.4 Fuses 34

5.2.5 EMC Compliant Electrical Installation 35

5.2.6 Control Terminals 37

6 How to Program 38

6.1 Programming with MCT 10 Set-up Software 38

6.2 Local Control Panel (LCP) 38

6.3 Menus 39

6.3.1 Status Menu 39

6.3.2 Quick Menu 39

6.3.3 Main Menu 47

6.4 Quick Transfer of Parameter Settings between Multiple Frequency Converters 48

6.5 Readout and Programming of Indexed Parameters 48

6.6 Initialize the Frequency Converter to Default Settings in two Ways 48

7 RS485 Installation and Set-up 49

7.1 RS485 49

7.1.1 Overview 49

7.1.2 Network Connection 50

7.1.3 Frequency Converter Hardware Set-up 50

7.1.4 Parameter Settings for Modbus Communication 50

7.1.5 EMC Precautions 51

7.2 FC Protocol Overview 51

7.3 Network Conguration 52

7.4 FC Protocol Message Framing Structure 52

Contents VLT®Compressor Drive CDS 803

7.4.1 Content of a Character (byte) 52

7.4.2 Telegram Structure 52

7.4.3 Telegram Length (LGE) 52

7.4.4 Frequency Converter Address (ADR) 52

7.4.5 Data Control Byte (BCC) 52

7.4.6 The Data Field 53

7.4.7 The PKE Field 54

7.4.8 Parameter Number (PNU) 54

7.4.9 Index (IND) 54

7.4.10 Parameter Value (PWE) 54

7.4.11 Data Types Supported by the Frequency Converter 55

7.4.12 Conversion 55

7.4.13 Process Words (PCD) 55

7.5 Examples 55

7.6 Modbus RTU Overview 56

7.6.1 Prerequisite Knowledge 56

7.6.2 What the User Should Already Know 56

7.6.3 Overview 56

7.6.4 Frequency Converter with Modbus RTU 57

7.7 Network Conguration 57

7.8 Modbus RTU Message Framing Structure 57

7.8.1 Introduction 57

7.8.2 Modbus RTU Telegram Structure 57

7.8.3 Start/Stop Field 58

7.8.4 Address Field 58

7.8.5 Function Field 58

7.8.6 Data Field 58

7.8.7 CRC Check Field 58

7.8.8 Coil Register Addressing 58

7.8.9 How to Control the Frequency Converter 60

7.8.10 Function Codes Supported by Modbus RTU 60

7.8.11 Modbus Exception Codes 61

7.9 How to Access Parameters 61

7.9.1 Parameter Handling 61

7.9.2 Storage of Data 61

7.10 Examples 62

7.10.1 Read Coil Status (01 hex) 62

7.10.2 Force/Write Single Coil (05 hex) 62

7.10.3 Force/Write Multiple Coils (0F hex) 63

7.10.4 Read Holding Registers (03 hex) 63

Contents Design Guide

7.10.5 Preset Single Register (06 hex) 64

7.10.6 Preset Multiple Registers (10 hex) 64

7.11 Danfoss FC Control Prole 65

7.11.1 Control Word According to FC Prole (8-10 Protocol = FC prole) 65

7.11.2 Status Word According to FC Prole (STW) (parameter 8-30 Protocol = FC pro-

le) 66

7.11.3 Bus Speed Reference Value 68

8 General Specications 69

8.1 Mains Supply Specications 69

8.1.1 Mains Supply 3x200–240 V AC 69

8.1.2 Mains Supply 3x380–480 V AC 70

8.2 General Specications 71

8.3 Acoustic Noise or Vibration 74

8.4 Derating according to Ambient Temperature and Switching Frequency 75

Index 76

Contents VLT®Compressor Drive CDS 803

1 Introduction

1.1 Purpose of the Manual

This design guide is intended for project and systems

engineers, design consultants, and application and product

specialists. Technical information is provided to understand

the capabilities of the frequency converter for integration

into motor control and monitoring systems. Details

concerning operation, requirements, and recommendations

for system integration are described. Information is proved

for input power characteristics, output for motor control,

and ambient operating conditions for the frequency

converter.

Also included are:

•Safety features.

•Fault condition monitoring.

•Operational status reporting.

•Serial communication capabilities.

•Programmable options and features.

Also provided are design details such as:

•Site requirements.

•Cables.

•Fuses.

•Control wiring.

•Unit sizes and weights.

•Other critical information necessary to plan for

system integration.

Reviewing the detailed product information in the design

stage enables developing a well-conceived system with

optimal functionality and eciency.

VLT®is a registered trademark.

1.2 Document and Software Version

This manual is regularly reviewed and updated. All

suggestions for improvement are welcome. Table 1.1 shows

the document version and the corresponding software

version.

Edition Remarks Software version

MG18N2xx – 1.20

Table 1.1 Document and Software Version

1.3 Safety Symbols

The following symbols are used in this manual:

WARNING

Indicates a potentially hazardous situation that could

result in death or serious injury.

CAUTION

Indicates a potentially hazardous situation that could

result in minor or moderate injury. It can also be used to

alert against unsafe practices.

NOTICE

Indicates important information, including situations that

can result in damage to equipment or property.

1.4 Abbreviations

°CDegrees celsius

A Ampere/AMP

AC Alternating current

AMA Automatic motor adaptation

AUG. American wire gauge

DC Direct current

EMC Electro magnetic compatibility

ETR Electronic thermal relay

FC Frequency converter

fM,N Nominal motor frequency

g Gram

Hz Hertz

IINV Rated inverter output current

ILIM Current limit

IM,N Nominal motor current

IVLT,MAX The maximum output current

IVLT,N The rated output current supplied by the

frequency converter

kHz Kilohertz

LCP Local control panel

m Meter

mA Milliampere

MCT Motion control tool

mH Millihenry inductance

min Minute

ms Millisecond

nF Nanofarad

Nm Newton meters

nsSynchronous motor speed

PM,N Nominal motor power

Introduction Design Guide

PCB Printed circuit board

PELV Protective extra low voltage

Regen Regenerative terminals

RPM Revolutions per minute

s Second

TLIM Torque limit

UM,N Nominal motor voltage

V Volts

Table 1.2 Abbreviations

1.5 Additional Resources

•VLT

Compressor Drive CDS 803 Quick Guide

provides basic information on mechanical

dimensions, installation and programming.

•VLT

Compressor Drive CDS 803 Programming

Guide provides information on how to program

and includes complete parameter descriptions.

•VLT

Compressor Drive CDS 803 Design Guide

entails all technical information about the

frequency converter and customer design and

applications.

•MCT 10 Set-up Software enables the user to

congure the frequency converter from a

Windows™based PC environment.

Danfoss technical literature is available in print from a local

Danfoss Sales Oce or at:

vlt-drives.danfoss.com/Support/Technical-Documentation/

1.6 Denitions

Frequency converter

IVLT,MAX

The maximum output current.

IVLT,N

The rated output current supplied by the frequency

converter.

UVLT, MAX

The maximum output voltage.

Input

The connected compressor

can start and stop with LCP

and the digital inputs.

Functions are divided into 2

groups.

Functions in group 1 have

higher priority than

functions in group 2.

Group

Reset, coasting stop, reset

and coasting stop, quick-

stop, DC braking, stop,

and the [O] key.

Group

Start, pulse start,

reversing, start reversing,

jog, and freeze output

Table 1.3 Control Commands

Compressor

fJOG

The motor frequency when the jog function is activated

(via digital terminals).

The motor frequency.

fMAX

The maximum compressor frequency.

fMIN

The minimum compressor frequency.

fM,N

The rated motor frequency (nameplate data).

The motor current.

IM,N

The rated motor current (nameplate data).

nM,N

The nominal motor speed (nameplate data).

PM,N

The rated motor power (nameplate data).

The instant motor voltage.

UM,N

The rated motor voltage (nameplate data).

Break-away torque

175ZA078.10

Pull-out

rpm

Torque

Illustration 1.1 Break-away Torque

ηVLT

The eciency of the frequency converter is dened as the

ratio between the power output and the power input.

Start-disable command

A stop command belonging to the group 1 control

commands, see Table 1.3.

Stop command

See control commands, Table 1.3.

References

Analog reference

A signal transmitted to the analog inputs 53 or 54, can be

voltage or current.

Introduction VLT®Compressor Drive CDS 803

Bus reference

A signal transmitted to the serial communication port (FC

port).

Preset reference

A dened preset reference to be set from -100% to +100%

of the reference range. Selection of 8 preset references via

the digital terminals.

RefMAX

Determines the relationship between the reference input at

100% full scale value (typically 10 V, 20 mA) and the

resulting reference. The maximum reference value set in

parameter 3-03 Maximum Reference.

RefMIN

Determines the relationship between the reference input at

0% value (typically 0 V, 0 mA, 4 mA) and the resulting

reference. The minimum reference value set in

parameter 3-02 Minimum Reference.

Miscellaneous

Analog inputs

The analog inputs are used for controlling various

functions of the frequency converter.

There are 2 types of analog inputs:

•Current input, 0–20 mA, and 4–20 mA.

•Voltage input, 0–10 V DC.

Analog outputs

The analog outputs can supply a signal of 0–20 mA, 4–20

mA, or a digital signal.

Automatic Motor Adaptation, AMA

AMA algorithm determines the electrical parameters for

the connected compressor at standstill.

Digital inputs

The digital inputs can be used for controlling various

functions of the frequency converter.

Digital outputs

The frequency converter features 2 solid-state outputs that

can supply a 24 V DC (maximum 40 mA) signal.

Relay outputs

The frequency converter features 2 programmable relay

outputs.

ETR

Electronic thermal relay is a thermal load calculation based

on present load and time. Its purpose is to estimate the

compressor temperature.

Initializing

If initializing is carried out (parameter 14-22 Operation

Mode), the programmable parameters of the frequency

converter return to their default settings.

Parameter 14-22 Operation Mode does not initialize

communication parameters.

Intermittent duty cycle

An intermittent duty rating refers to a sequence of duty

cycles. Each cycle consists of an on-load and an o-load

period. The operation can be either periodic duty or none-

periodic duty.

LCP

The local control panel (LCP) makes up a complete

interface for control and programming of the frequency

converter. The control panel is detachable and can be

installed up to 3 m (9.8 ft) from the frequency converter,

that is, in a front panel with the installation kit option.

lsb

Least signicant bit.

MCM

Short for Mille Circular Mil, an American measuring unit for

cable cross-section. 1 MCM ≡0.5067 mm2.

msb

Most signicant bit.

On-line/O-line parameters

Changes to on-line parameters are activated immediately

after the data value is changed. To activate the o-line

parameters, press [OK].

PI controller

The PI controller maintains the desired speed, pressure,

temperature, and so on, by adjusting the output frequency

to match the varying load.

RCD

Residual current device.

Set-up

Parameter settings in 2 set-ups can be saved. Change

between the 2 parameter set-ups and edit 1 set-up, while

another set-up is active.

Slip compensation

The frequency converter compensates for the compressor

slip by giving the frequency a supplement that follows the

measured compressor load keeping the compressor speed

almost constant.

Smart logic control (SLC)

The SLC is a sequence of user-dened actions executed

when the associated user-dened events are evaluated as

true by the SLC.

Thermistor

A temperature-dependent resistor placed where the

temperature is to be monitored (frequency converter or

compressor).

Trip

A state entered in fault situations, for example, if the

frequency converter is subject to an overtemperature or

when the frequency converter is protecting the

compressor, process, or mechanism. Restart is prevented

until the cause of the fault has disappeared and the trip

state is canceled by activating reset or, sometimes, by

Introduction Design Guide

being programmed to reset automatically. Do not use trip

for personal safety.

Trip lock

A state entered in fault situations when the frequency

converter is protecting itself and requiring physical

intervention, for example, if the frequency converter is

subject to a short circuit on the output. A locked trip can

only be canceled by cutting o mains, removing the cause

of the fault, and reconnecting the frequency converter.

Restart is prevented until the trip state is canceled by

activating reset or, sometimes, by being programmed to

reset automatically. Trip lock may not be used for personal

safety.

VT characteristics

Variable torque characteristics used for pumps and fans.

VVC+

If compared with standard voltage/frequency ratio control,

voltage vector control (VVC+) improves the dynamics and

the stability, both when the speed reference is changed

and in relation to the load torque.

1.7 Power Factor

The power factor indicates to which extent the frequency

converter imposes a load on the mains supply. The power

factor is the ratio between I1and IRMS, where I1is the

fundamental current, and IRMS is the total RMS current

including harmonic currents. The lower the power factor,

the higher the IRMS for the same kW performance.

Powerfactor =3 × U×I1 × COSϕ

3 × U×IRMS

The power factor for 3-phase control:

Powerfactor =I1×cosϕ1

IRMS

=I1

IRMS

sincecosϕ1 = 1

IRMS =I1

2+I5

2+I7

2 +  .  .  + In

A high-power factor indicates that the dierent harmonic

currents are low.

The frequency converters built-in DC coils produce a high-

power factor, which minimizes the imposed load on the

mains supply.

Introduction VLT®Compressor Drive CDS 803

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