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Instructions for Danfoss models including: VZH028, VZH044, VZH052, VZH065, VZH028 Series Inverter Compressors, VZH028 Series, Inverter Compressors, Compressors
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DocumentDocumentInstructions Danfoss inverter compressors VZH028-VZH065 Condensing temperature (°C) A B E F G VZH028-044 VZH052-065 C D 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 Operating limits VZH028-044 operating map - R410A (SH 6 K) 75 70 Voltage: 400-460V/208-230V 65 60 3600-6000 rpm 55 2400-6000 rpm 2400-6000 rpm 50 45 1800-6000 rpm 1200-6000 rpm 40 35 30 25 20 900-6000 rpm 15 10 5 0 -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 Evaporating temperature (°C) VZH052-065 operating map - R410A (SH 6 K) 75 70 65 60 2400-6000rpm 55 50 45 4200-6000rpm 1800-6600rpm 40 35 30 25 1000-6600rpm VZH67F Map 20 Solid line bondaries: 15 SH=6K 10 Dash line bondaries: 5 need ensure Tdis 0 -35 -30 -25 -20 -15 -10 -5 0 <135°C 5 10 15 20 25 30 35 40 Evaporating temperature (°C) Condensing 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 VZH028-044 Ring connect screw terminals C & Q terminal box type VZH052-065 push push push VZH028 - VZH065 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 Driver power Driver model VZH028-J/G 6kW CDS803 VZH035-J/G 7.5kW CDS803 VZH044-J/G 10kW CDS803 VZH028-H 7.5kW CDS303 VZH035-H 11kW CDS303 VZH044-H 11kW CDS303 VZH052-J 11kW CDS303 VZH065-J 11kW CDS303 VZH052-G 11kW CDS303 VZH065-G 15kW CDS303 VZH052-H 15kW CDS303 VZH065-H 22kW CDS303 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. © Danfoss | DCS (CC) | 2021.03 8510280P01AA - AN233086441027en-000501 | 1 Instructions - 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. Basic connections - 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 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. Oil level switch assembly 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. * For LC-PR, make sure the cable outlet downside or upside vertically. Electrical connections / Wiring for Oil level sensor See at the correct diagram corresponding to different power supply models for proper wiring 3 21 4 1: Power supply wire 2: Power supply wire 3: Output wire 4: Not used LC-XN 24VAC 0VAC 24VAC 230VAC L1 L2 L3 N 1 2 LC-XN 3 External Load / Relay 24VDC 0VDC 24VDC LC-PR 2 1: Power supply (L or 24V) 3 1 2: Output NO CONTACT 3: Power supply (N or 0V) 4: Output COMMON 4 L / 24V N / 0V 1 4 LC-PR 3 2 External Load External Load / Relay 1 2 LC-XN 3 External Load / Relay 1 2 LC-XN 3 1 Introduction These instructions pertain to the VZH028VZH065 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 VZH, 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 2 | AN233086441027en-000501 - 8510280P01AA © Danfoss | DCS (CC) | 2021.03 Instructions 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 (Low side) Maximum compressor test pressure (High side) 30 bar for VZH028-044 33.3 bar for VZH052-065 41.1 bar Maximum pressure difference between high side and low side of the compressor 36 bar · 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 CDS 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 3.6 kg, For VZH052-065, the refrigerant charge limit is 5.4 kg. Above this limit; protect the compressor against liquid flood-back with a pump-down cycle not lower than 1.18 bar (g) for VZH028-044/1.8 bar (g) for VZH052-065 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) for VZH028-044. Minimum pressure 1.5 bar for VZH052-065. · 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 12s for each start. 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 © Danfoss | DCS (CC) | 2021.03 8510280P01AA - AN233086441027en-000501 | 3 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 A/S 6430 Nordborg Denmark 4 | AN233086441027en-000501 - 8510280P01AA © Danfoss | DCS (CC) | 2021.03