VZH044 Inverter Compressors
“
Product Information
Specifications:
- Model: VZH028-VZH044
- Supply Voltage Range: 400-460V/208-230V
- Refrigerant: R410A
- Max Operating Current: 60-100 rps
- Operating Limits: Refer to the VZH Operating Map
Product Usage Instructions
Electrical Connections:
The VZH028 – VZH044 compressors can be powered by the dedicated
variable speed drive or third party drive. When using a Danfoss
drive, ensure compatibility with the compressor model.
Installation:
Installation and servicing should be carried out by qualified
personnel only. Follow the provided instructions and refrigeration
engineering practices for proper installation, commissioning,
maintenance, and service.
Operating Guidelines:
- Compressor must be used only for its designated purpose and
within its scope of application. - Ensure the compressor is handled with care and caution during
operation. - Always wear protective goggles and work gloves when servicing
the compressor.
Electrical Connections/Wiring:
Ensure that compressor terminals T1, T2, T3 are connected to the
frequency converter terminals 96, 97, 98 respectively. Shield the
compressor motor cable and connect the armored part to ground on
both cable ends.
Oil Level Switch Assembly:
Install the screw-in optical part on the oil level switch port
and the electrical part on the optical part. Ensure the cable
outlet is positioned vertically downwards.
FAQ (Frequently Asked Questions)
Q: Can the compressor be operated with a third-party variable
speed drive?
A: Yes, the VZH028 – VZH044 compressors can be powered by a
dedicated variable speed drive or a third-party drive. Ensure
compatibility with the compressor model when using a third-party
drive.
Q: What is the recommended refrigerant for these
compressors?
A: The recommended refrigerant for these compressors is
R410A.
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Instructions
Danfoss inverter compressors
VZH028-VZH044
A
B
E
F
G
C D
Single version Operating limits
Manifold version
A: Model number B: Serial Number C: Refrigerant D: Manufacturing year E: Supply voltage range F: Max operating current G: Lubricant type and nominal charge
Condensing temperature (°C)
VZH operating map – R410A (SH 6 K)
75
Voltage: 400-460V/208-230V
70
65
60
60-100 rps
55
50 45
40
40-100 rps 30-100 rps
20-100 rps
35
30
25
20
15-100 rps
15
10
5
0
-40
-35
-30
-25
-20
-15
-10
-5
0
5
10
15
20
25
Evaporating temperature (°C)
All the above limits, temperatures and speeds, are secured by parameters in the drive and application controller softwares.
Electrical connections
Quick connect spade terminals
push push
push
VZH028 – VZH044 compressors can be powered by the dedicated variable speed drive or third party drive.
When Danfoss drive is selected, check carefully for compatibility between compressor model and variable speed drive.
Compressor model VZH028 VZH035 VZH044
Variable speed drive rated power output
6 kW 7.5 kW 10 kW
Note : These instructions replace instructions in grommet kit.
Installation and servicing of the compressor by qualified personnel only. Follow these instructions and sound refrigeration engineering practice relating to installation, commissioning, maintenance and service.
The compressor must only be Never operate Under all circumstances, The compressor must The compressor is delivered under
used for its designed purpose(s) c o m p r e s s o r the EN378 (or other applicable be handled with nitrogen gas pressure (between
and within its scope of application without terminal local safety regulation)
caution in the vertical 0.3 and 0.4 bar / 4 and 6 psi). Do
(refer to «operating limits»). Consult box cover in place requirements must be fulfilled. position (maximum not disassemble bolts, plugs,
Application guidelines and datasheet and secured.
Wear protective goggles and offset from the fittings, etc… unless all pressure
available from cc.danfoss.com
work gloves.
vertical : 15°).
has been relieved from the
compressor.
– Depending on the frequency converter version, the physical position of individual connectors may differ from below diagram.
– Always make sure that the compressor terminals T1, T2, T3 are connected to the frequency converter terminals 96, 97, 98 respectively.
– The compressor motor cable must be shielded and the armoured part must be connected to ground on both cable ends; at the side of the
Basic connections
compressor and at the side of the frequency converter. – Use an EMC cable gland for cable installation and perfect grounding; The metallic terminal box of the compressor has a paint-free surface around the connection hole for better conductivity. – A low pressure safety switch is mandatory to avoid compressor vacuum operation. – At start-up, verify that the compressor rotates in the right direction and pumps.
© Danfoss | DCS (CC) | 2016.06
FRCC.PI.035.A2.02 | 1
Instructions
Oil level switch assembly
L1
91 L1
L2
92 L2
L3
93 L3
95 PE
U 96 V 97 W 98
PE 99
T1/U T2/V T3/W
Install the screw-in optical part on oil level switch port. (Factory preset for manifold version VZH compressor.)
Install the electrical part on optical part. Make sure the cable outlet downside vertically
Electrical connections / Wiring
3 21
4
1: Power supply wire 2: Power supply wire
3: Output wire 4: Not used
See at the correct diagram corresponding to different power supply models for proper wiring
24VDC OVDC
24VDC MODEL
1
2
Sensor 3
External Load / Relay
24VAC OVAC
24VAC MODEL
1
2
Sensor 3
External Load / Relay
230VAC MODEL
L
N
1
2
Sensor 3
External Load / Relay
45 Ana out or Dig out 42 Ana out or Dig out 50 out +10 V 53 Ana in 54 Ana in 55 Ana in/out COM
12 +24V 18 Dig in 19 Dig in 27 Dig in/out 29 Dig in/out 20 Dig in COM
CDS803
RELAY 2 RELAY 1
NC NO 02 COM 01 NC 06 NO 05 COM 04
N- RS485 69 P+ RS485 68 COM RS485 61
Legends: Ana: Dig: in: out: COM: NC: NO:
Analogue Digital Input Output Common Normally-closed Normally-open
91,92,93 95
42,45 50 53 54 55 12 18 19 27 29 20 98 97 96 99
03,02,01
06,05,04
69,68 61
3 phases mains input Earth 0/4-20 mA Analague Output or Digital Output +10V DC Output 0-10V or 4-20mA Analague Input 0-10V or 4-20mA Analague Input Com Analague In/Out External On/Off(NO) External On/Off(NO) Digital Input Safety Device Digital Input Com Digital Input To Compressor T3 To Compressor T2 To Compressor T1 Earth Relay 1
Relay 2
RS485 Bus RS485 Bus Com
-: Optional connection X: Mandatory connection
Open loop
x x x x x x x x x x x –
Process loop
x x x x x x x x x x –
The CDS803 frequency converter is factory preset with parameters for the open loop control principle. The process loop control principle can be selected by changing parameters in the «Quick menu». Open loop: preset on input 53 0 – 10 V control Frequency converter in slave mode Process loop: preset on input 54 4 – 20 mA control Frequency converter under own PID controller
FRCC.PI.035.A2.02
© Danfoss | DCS (CC) | 2016.06 | 2
Instructions
1 Introduction
These instructions pertain to the VZH08VZH044 variable scroll compressors used for airconditioning and reversible heat pump systems in residential applications. They provide necessary information regarding safety and proper usage of this product.
2 Handling and storage
· Handle the compressor with care. Use the dedicated handles in the packaging. Use the compressor lifting lug and use appropriate and safe lifting equipment.
· Store and transport the compressor in an upright position.
· Store the compressor between -35°C and 55°C / -31°F and 131°F.
· Don’t expose the compressor and the packaging to rain or corrosive atmosphere.
3 Safety measures before assembly
Never use the compressor in a flammable atmosphere. · The compressor ambient temperature may not
exceed 50°C during off-cycle. · Mount the compressor on a horizontal flat
surface with less than 7° slope. · When installing a compressor model VRJ,
use equipment specifically reserved for HFC refrigerants, which was never used for CFC or HCFC refrigerants. · Use clean and dehydrated refrigeration-grade copper tubes and silver alloy brazing material. · Use clean and dehydrated system components. · The piping connected to the compressor must be flexible in 3 dimensions to dampen vibrations. · The compressor must always be mounted using the rubber grommets supplied with the compressor.
4 Assembly
· Slowly release the nitrogen holding charge through discharge and suction ports.
· Connect the compressor to the system as soon as possible to avoid oil contamination from ambient moisture.
· Avoid material entering into the system while cutting tubes. Never drill holes where burrs cannot be removed.
· Braze with great care using state-of-the-art technique and vent piping with nitrogen gas flow.
· Connect the required safety and control devices.
5 Leak detection
Never pressurize the circuit with oxygen or dry air. This could cause fire or explosion. · Do not use leak detection dye. · Perform a leak detection test on the complete
system. · The test pressure must not exceed:
Maximum compressor test pressure 30 bar
(Low side) Maximum compressor test pressure 41.1 bar
(High side) Maximum pressure difference
36 bar
between high side and low side of the
compressor · When a leak is discovered, repair the leak and
repeat the leak detection.
6 Vacuum dehydration
· Never use the compressor to evacuate the system.
· Connect a vacuum pump to both the LP & HP sides. · Pull down the system under a vacuum of 500
µm Hg (0.67 mbar) / 0.02 inch Hg absolute. · Do not use a mega ohmmeter nor apply power
to the compressor while it is under vacuum as this may cause internal damage.
7 Electrical connections
· Switch off and isolate the main power supply. · Before touching any potentially live part of the
drive, wait at least 4 minutes. · The compressor is protected against excess
current by the frequency converter. Follow local regulations regarding power line protection.The compressor must be connected to ground. · Use 6.3 mm tabs for quick connect spade terminals. · Use a self-tapping screw to connect the ground conductor to the compressor. · Care must be taken during installation to ensure that the compressor operates in the correct direction. T1 (U), T2 (V) and T3 (W) terminals of compressor and drive U, V, W must match. Please refer to drawings for typical wiring connections and examine the specific wiring diagram located in the frequency converter package. For further details, refer to the application guidelines. · Mounting: The base frame of the frequency converter must be very well fixed to the support to ensure a very good continuity between the ground potential of all electrical panels and electrical boxes of the system. · Wiring: All control wires have to be of a screeened design. The cable for electrical motor supply has to be of a shielded design as well. Correct earthing of the shield cover has to be done using the method shown on drawings, every time this one has to be earthed on each end of the cables. Distinct cable trays must be used for control and motor supply. · The frequency converter ensures direct motor protection and the factory set parameters are such to protect the motor over all current malfunctions. An external overload is not necessary. · Set the frequency converter parameters in accordance with Danfoss recommendations for the CDS803 frequency converter and VZH variable speed compressor. · Refer to variable speed drive manual for electrical connections details and installation. · Compressor motor protection is provided by the variable speed drive.
8 Filling the system
· Keep the compressor switched off. · Fill the refrigerant in liquid phase into the
outlet of the condenser or the liquid receiver. The charge must be as closed as possible to the nominal system charge to avoid low pressure operation and excessive superheat. For VZH028-044, the refrigerant charge limit is 3.6kg.Above this limit; protect the compressor against liquid flood-back with a pump-down cycle not lower than 1.18 bar (g) or a suction line accumulator. · Never leave the filling cylinder connected to the circuit.
9 Verification before commissioning
Use safety devices such as safety pressure switch and mechanical relief valve in compliance with both generally and locally applicable regulations and safety standards. Ensure that they are operational and properly set.
Check that the settings of high-pressure switches do not exceed the maximum service pressure of any system component. ·A low-pressure switch is mandatory to avoid vacuum operation. Minimum setting 1.0 bar (g) · Verify that all electrical connections are
properly fastened and in compliance with local regulations. · When using discharge temperature sensor, ensure that the discharge temperature sensor is correctly installed and fitted to the discharge piping (6 inches from discharge fitting) and well connected, especially after maintenance operations. · After comissioning it is strongly recommended to keep the frequency converter always energized.
10 Start-up
· Never start the compressor when no refrigerant is charged.
· Do not provide any power to the drive unless suction and discharge service valves on compressor are open, if installed.
· Energize the drive. The compressor must start, according to defined ramp-up settings. If the compressor does not start, check wiring conformity.
· Check the frequency converter control panel: If any alarm is displayed check the wiring and in particular the polarity of the control cables. If an alarm is shown, refer to the frequency converter application manual. Verify in particular the combination of compressor, frequency converter and refrigerant.
· Check current draw and voltage levels on the mains. The values for the compressor electrical motor can be directly displayed on the frequency converter control panel.
· The optimum compressor suction superheat is around 6K. The maximum allowed superheat is 30K.
· Eventual reverse rotation can be detected by following phenomena; the excessive noise, no pressure differential between suction and discharge, and line warming rather than immediate cooling. A service technician should be present at initial start-up to verify that wiring from drive to compressor is properly phased and that the compressor is rotating in the correct direction.
· Note that a 300 seconds period is necessary between 2 starts, a shorter period will be not allowed by the drive. The minimum running time is 60s for each start.
3 | © Danfoss | DCS (CC) | 2016.06
FRCC.PI.035.A2.02
11 Check with running compressor
Check current draw and voltage. Measurement of amps and volts during running conditions must be taken at other points in the power supply, not in the compressor electrical box. · Check suction superheat to reduce risk of
slugging. · Observe the oil level at start and during
operation to confirm that the oil level remains visible. Excess foaming in oil sight glass indicates refrigerant on the sump. · Monitor the oil sight glass for 1 hour after system equilibrium to ensure proper oil return to the compressor. This oil check has to be done over the speed range to guarantee: – a good oil return at low speed with minimum gas velocity. – a good oil management at high speed with maximum oil carry over. · Respect the operating limits. · Check all tubes for abnormal vibration. Movements in excess of 1.5 mm / 0.06 inch require corrective measures such as tube brackets. · When needed, additional refrigerant in liquid phase may be added in the low-pressure side as far as possible from the compressor. The compressor must be operating during this process. · Do not overcharge the system. · Never release refrigerant to atmosphere. · Before leaving the installation site, carry out a general installation inspection regarding cleanliness, noise and leak detection. · Record type and amount of refrigerant charge as well as operating conditions as a reference for future inspections. · Compressor failure to build up pressure: Check all bypass valves in the system to ensure that none of these has been opened. Also check that all solenoid valves are in their proper position. · Abnormal running noise: Ensure the absence of any liquid flood-back to the compressor by means of measuring the return gas superheat and compressor sump temperature. The sump should be at least 6K above the saturated suction temperature under steady-state operating conditions. · The high-pressure switch trips out: Check condenser operations (condenser cleanliness, fan operation, water flow and water pressure valve, water filter, etc.). If all these are OK, the problem may be due to either refrigerant overcharging or the presence of a noncondensable (e.g. air, moisture) in the circuit. · The low-pressure switch trips out: Check evaporator operations (coil cleanliness, fan operations, water flow, water filter, etc.), liquid refrigerant flow and pressure drops (solenoid valve, filter dryer, expansion valve, etc.), refrigerant charge. · Low refrigerant charge: The correct refrigerant charge is given by the liquid sight glass indication, the condenser delta T in relation to the refrigerant pressure tables (pressuretemperature), the superheat and the subcooling, etc. (if additional charge is deemed necessary, refer to section 8).
· Compressor short cycling: The number of cycles shall never exceed 12 starts per hour.
12 Maintenance
Internal pressure and surface temperature are dangerous and may cause permanent injury. Maintenance operators and installers require appropriate skills and tools. Tubing temperature may exceed 100°C / 212°F and can cause severe burns.
Ensure that periodic service inspections to ensure system reliability and as required by local regulations are performed. To prevent system related compressor problems, following periodic maintenance is recommended: · Verify that safety devices are operational and
properly set. · Ensure that the system is leak tight. · Check the compressor current draw by reading
one of the parameters via Modbus. · Confirm that the system is operating in a way
consistent with previous maintenance records and ambient conditions. · Check that all electrical connections are still adequately fastened. · Keep the compressor clean and verify the absence of rust and oxidation on the compressor shell, tubes and electrical connections. · Acid / moisture content in system and oil should be checked regularly.
13 – Warranty
Always transmit the model number and serial number with any claim filed regarding this product. Use the fault memory of the frequency converter to recover the fault descriptions before initializing the system and even before shutting off the power. Variable speed drive model and serial number must also be transmitted with the claim. The product warranty may be void in following cases: · Absence of nameplate. · External modifications; in particular, drilling,
welding, broken feet and shock marks. · Compressor opened or returned unsealed. · Rust, water or leak detection dye inside the
compressor. · Use of a refrigerant or lubricant not approved
by Danfoss. · Any deviation from recommended instructions
pertaining to installation, application or maintenance. · Use in mobile applications. · Use in explosive atmospheric environment. · No model number or serial number transmitted with the warranty claim.
14 Disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site.
Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed 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 being necessary in specifications already agreed. All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.
4 | © Danfoss | DCS (CC) | 2016.06
FRCC.PI.035.A2.02
Documents / Resources
 |
Danfoss VZH044 Inverter Compressors [pdf] Instructions VZH028, VZH035, VZH044, VZH044 Inverter Compressors, Inverter Compressors, Compressors |