Danfoss VZH052 Series User Manual Download

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Danfoss scroll compressors

VZH052-065

Single

R410A

Application guidelines

http://cc.danfoss.com

Summary of Contents for VZH052 Series

Page 1: ...Danfoss scroll compressors VZH052 065 Single R410A Application guidelines http cc danfoss com ...

Page 2: ......

Page 3: ...tion 26 Compressor sound radiation 26 Mechanical vibrations 27 Gas pulsation 27 Manage superheat 28 Requirement 28 System evaluation 28 Test criteria and solutions 29 Manage off cycle migration 30 Requirement 30 System evaluation 30 Manage operating envelope 32 Requirement 32 System evaluation 33 Manage speed limit 37 Speed limit requirement 37 Start Stop Ramp setting 37 Control logic 38 Safety co...

Page 4: ...are highlighted with the following icons This icon indicates instructions to avoid safety risk This icon indicates instructions to avoid reliability risk The purpose of this guideline is to help customers qualify compressors in the unit You are strongly advise to follow these instructions For any deviation from the guidelines please contact Danfoss Technical Support In any case Danfoss accepts no ...

Page 5: ...ing the effort of the motor and its electrical consumption and improving the system s seasonal energy efficiency How do IDVs work Intermediate discharge valves for better efficiency at low pressure ratio Optimized scrolls for better part load efficiency New distributed IPM motor lead to higher power factor High speed oil circulation minimized by a oil return tube Linear control oil pump PVE 32 lub...

Page 6: ...closure protection IP rating E20 E55 P11K P15K P22K B N A G C 065 Z H V Variable speed Family VZH scroll Lubricant PVE 32 160 HV lubricant R410A refrigerant Swept volume in cm rev Evolution index Motor protection type N no internal motor protection protection by drive Equipement version A brazed connections single version D brazed connections unified version Motor voltage code to CDS303 G 380 480V...

Page 7: ...ence class H2 H3 or HX 4 Printed Circuit Board PCB coated When the compressor size and mains voltage have been defined in the above selection criteria the code number tables from the Ordering information and packaging section provides the appropriate frequency converter sizes and up to four corresponding code numbers for each compressor model Note this compressor is equipped with a six pole electr...

Page 8: ... 0 3 9 138 11 7 413 14 1 498 25 8 911 1 57 53 35 77 VZH052 52 1 3 2 3 1 109 9 4 332 11 3 399 20 6 727 1 57 53 35 77 Mains supply voltage T2 200 240 V 10 3 phase T4 380 480 V 10 3 phase T6 525 600V 10 3 phase Supply frequency 50 60 Hz Output voltage 0 100 of supply voltage Inputs 6 digital 0 24V 2 analog 0 10V or 4 20mA scalable Programmable outputs 2 digital 0 24V 1 analog 0 4 20mA 2 relay Protect...

Page 9: ... between 2 and 3 will be opened internally there will be no current flowing through load or coil of external relay relay is open Enough oil Circuit between 2 and 3 will be closed internally there will be current flowing through load or coil of external relay relay is close Note For 24VDC output voltage in case of lack of oil is 13V DC and not 0V For customers who needs UL certificates please order...

Page 10: ...5 183 5 7 22 436 17 17 403 15 87 261 10 28 190 5 7 5 190 5 7 5 8590007 Unified VZH052 065 183 5 7 22 436 17 17 403 15 87 261 10 28 190 5 7 5 190 5 7 5 8590013 VZH052 065G J H H H1 ΦD H2 L2 L1 H H1 ΦD H2 L2 L1 Single version Unified version EMC bracket to terminations of shielded wire Earth grounding Mounting Grommet Terminal box Ø 41 29 5 Recommended torque for mounting bolts 11 Nm 1 Nm Ø11 PRODUC...

Page 11: ... be used for a visual check of oil amount and condition 2 Schrader The oil fill connection and gauge port is a 1 4 male flare connector incorporating a Schrader valve Compressor models Brazed connection size Rotolock adaptor set adaptor gasket sleeve nut Rotolock adaptor adaptor only Rotolock Solder sleeve ODF Code Number Code Number VZH052 065 Suction 7 8 1 1 4 7 8 120Z0128 120Z0367 Discharge 3 4...

Page 12: ...or cooling Min 100 200 Clearance above for cooling Frequency converter dimensions depend on supply voltage IP rating and power The table below gives an overview of the overall dimensions and different drive enclosures B1 B4 Details for each drive enclosure are on the following pages Enclosure Height Width Depth Mounting hole Max Weight Frame IP Class A A1 a B b C d e f mm inch mm inch mm inch mm i...

Page 13: ... 200 240V 3ph 50Hz 60Hz 10 G 380 480V 3ph 50Hz 60Hz 10 H 525 600V 3ph 50Hz 60Hz 10 Rated Load Amp value is the current value at maximum load in the operating envelope and at maximum speed and rated drive input voltage RLA is the measured value at the compressor terminals after the drive RLA Rated Load Amp MOC Max Operating Current Wiring connections Max operating current is the maximum continuous ...

Page 14: ...0 KLS R50 PKZM4 50 PKZM4 63 3x525 600V CDS303 15kW 63A gG KTS R 45 JKS 45 JKJS 45 5014006 050 KLSR045 PKZM4 50 PKZM4 63 CDS303 22kW 63A gG KTS R 60 JKS 60 JJS 60 5014006 063 KLSR060 NZMB1 A100 NZMB1 A100 From network to frequency converter From frequency converter to compressor Type mm AWG Type mm AWG 200 240 V CDS303 11kW 10 8 VZH052 J 10 8 CDS303 11kW 16 6 VZH065 J 16 6 380 400 V CDS303 11kW 4 1...

Page 15: ...tching the drive will provide correct phase supply to the compressor and reverse rotation will be not possible CDS terminal U 96 to VZH terminal T1 CDS terminal V 97 to VZH terminal T2 CDS terminal W 98 to VZH terminal T3 If compressor T1 T2 T3 and drive U V W terminals are not matching the compressor can operate in a reverse rotation This results in excessive noise no pressure differential betwee...

Page 16: ...15 tilted spaying splashing jetting powerful jetting temporary immersion continuous immersion VZH scroll compressors are not equipped with an internal motor protector Motor protection is provided by the variable speed drive All parameters are factory preset in order to guaranty locked rotor or overload current protection When a warning situation is reached in the current control the CDS frequency ...

Page 17: ...ive 2014 35 EU Internal free volume CE European Directive VZH code G code J UL Underwriters Laboratories All VZH models EMC Class A Group 1 2014 30 EU VZH compressor and drive package CCC VZH code G Products Internal free volume at LP side without oil lite cu inch VZH052 4 7 287 VZH065 4 7 287 Products VZH052 065 Declaration of conformity ref Low voltage directive 2014 35 EU Contact Danfoss PRODUC...

Page 18: ... penetrate and act as an abrasive This leads to bearing damage and fan failure Under the conditions described above it is advisable to clean the frequency converter during periodic maintenance Remove dust off the heat sink and fans and clean the filter mats For optimal cooling conditions mount the drive on vertical position Allow a free air passage above and below the frequency converter See Table...

Page 19: ...talled on a wall or on a back plate to ensure proper cooling Do not place the drive under direct sunlight Insulation inside the electrical panel can reduce impact of sun radiation Test at the unit at highest ambient maximum load is recommended Look for over temperature drive alarm The drive could operate lower to 10C with proper operation such as inside the cabinet install the space heater However...

Page 20: ...C correct installation of an frequency drive CDS303 PLC etc Panel Grounding rail Decoupling plate Cable insulation stripped All cable entries in one side of panel Motor cable Motor 3 phases and protective ground Reinforced protective ground L1 L2 L3 PE Mains supply Control cables PLC Min 0 025 in 16 mm Equalizing cable Min 7 9 in 200 mm between control cables motor cable and mains cable EMC qualif...

Page 21: ...rference at different frequency Ferrite core each line should snatch one turn on it Ferrite cores should be as close as possible to the drive Mechanical dimension The dimension of the ferrite core depends on the actual cable size which should be specified by the OEM depending on the unit design ambient temperature the wire material current etc The table below is a recommendation Wire sizes Mechani...

Page 22: ...3 PE T1 T2 T3 PE Comp ON OFF Start Stop 24V CC 150mA max 24V CC Digital Input Digital Input Digital Input Digital Input Digital Output Digital Input Digital Input Common Analog Output Common Analog Inputs Common COM Serial P Communication N RS 485 Analog Output 1 0 4 20mA Safe Stop Input SCHEMATIC DIAGRAM CDS 303 HP switch 0 10V DC speed signal VZH Alarm Contactor Fuses 3 phase L2 L1 91 92 93 95 9...

Page 23: ...ow 3 Piping should be designed with adequate three dimensional flexibility to avoid excess vibration It should not be in contact with the surrounding structure unless a proper tubing mount has been installed For more information on noise and vibration see section on Sound and vibration management 4 The design in this guideline is for short circuit application However for long circuit and split sys...

Page 24: ... mounting General requirements Single requirements Compressors used in single applications must be mounted with flexible grommets During operation the maximum inclination from the vertical plane must not exceed 7 degrees All compressors are delivered with four rubber grommets and metal sleeves Compressors must always be mounted with these grommets Recommended torque for mounting bolts 11 Nm 1 Nm S...

Page 25: ...nt charge in weight Above 3 look for potential oil trap in the system 2 Adjust oil boost function for more details see section Oil management logic 3 Oil separator can be added A Manage oil in the circuit R Requirement System evaluation Test criteria and solutions Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped...

Page 26: ...d power dB A Attenuation dBA Sound power dB A Attenuation dBA VZH052 VZH065 60 79 9 79 9 79 9 120Z5084 90 85 9 85 9 85 9 Sound power and attenuation are given at ARI conditions measured in free space Attenuation given with acoustic hood Materials are UL approved Mitigations methods We can consider two means to reduce compressors sound radiations 1 Acoustic hoods are quick and easy to install and d...

Page 27: ...uld be challenging on a variable system as all resonant frequencies between min speed to maximum speed will be exited It is mandatory to check that piping vibrations are acceptable across speed range This test can be done by increasing slowly speed and monitoring piping behavior through strain gage acceleration or displacement measurement As alternative visual check with strobe light can also emph...

Page 28: ...d flood back can cause oil dilution and in extreme situations lead to liquid slugging that can damage compression parts Requirement System evaluation In steady state conditions the expansion device must ensure a suction superheat within 5K to 30K 9 to 54 F Use the table in relation with the application to quickly evaluate the potential tests to perform Application Tests to perform Non reversible L...

Page 29: ...mode Suction superheat 5K 1 Check expansion valve selection and setting For Thermostatic expansion valve TXV check bulb position For Electronic expansion valve EXV check measurement chain and PID 2 Add a suction accumulator Transient Tests must be carried out with most unfavorable conditions fan staging compressor staging Oil superheat shall not be more than 30 sec below the safe limit defined in ...

Page 30: ...liquid refrigerant must not flow massively to compressor The charge limit is a threshold beyond with some protective measures must be taken to limit risk of liquid slugging and extreme dilution at start Use the table below in relation with the system charge and the application to quickly define necessary safeties to implement Charge limit is defined in table below Models Refrigerant charge limit k...

Page 31: ... solenoid valve LLSV A LLSV is used to isolate the liquid charge on the condenser side thereby preventing against charge transfer to the compressor during off cycles The quantity of refrigerant on the low pressure side of the system can be further reduced by using a pump down cycle in association with the LLSV Pump down cycle By decreasing pressure in the sump pump down Evacuates refrigerant from ...

Page 32: ... below nominal evap pressure with minimum of 1 8 bar g 22 psi below nominal evap pressure with minimum of 26psig Maximum allowable pressure on high pressure side according to PED regulation Condensing temperature C Condensing temperature F Evaporating temperature C Evaporating temperature F VZH operating envelop R410A SH5K 9 F Voltage 200 240V 380 480V 525 600V 40 0 5 10 15 20 25 30 35 40 45 50 55...

Page 33: ...ifferent parameter to avoid unit tripping On top of suction and discharge pressure limitations the discharge T must remain below 135 C 275 F Low pressure switch and high pressure switch remain necessary as an ultimate protection The whole envelope can be used on the whole speed range see Single application envelope Depending on speed range needed two types of controls to be considered Speed range ...

Page 34: ... envelope control Speed range 2400 allowed Test N Purpose Test condition Pass criteria Solutions 1 Check reaction of system to oil boost Stabilized the system in area below minimum speed 2400RPM until oil boost happen No unsafties happen Superheat requirement fullfilled Modify ramp up Modify superheat control Manage operating envelope Controller needs to manage speed limitation according to operat...

Page 35: ...rating range will cause serious damage to the compressor The discharge gas thermostat accessory kit code 7750009 includes all components required for installation as shown on the right DGT installation must respect below requirements The thermostat must be attached to the discharge line within 150 mm 5 91 inch from the compressor discharge port and must be thermally insulated and tightly fixed on ...

Page 36: ... to be done at both max and min operating conditions to guarantee the valve closes enough on the min and opens far enough on the max Complementary to MOP the unit controller can increase compressor speed to keep evaporating T lower than limit In steady state the condensing T must be maintained at a T within envelope This can be done by using fan speed controller or constant pressure valve Keep con...

Page 37: ...ion Default value s 1 71 Start delay keep running 3000 RPM within a certain duration 60 3 41 Ramp 1 ramp up time It is used to define speed ramp up slope Speed ramp up slope is defined under condition that increases compressor speed from 0 rpm to 6000 rpm in a certain period s ramp1 ramp up time Eg if current speed is 3000rpm and desired speed is 4000rpm then compressor will reach 4000 rpm in 15s ...

Page 38: ...t The LP switch tolerance must not allow for vacuum operations of the compressor LP switch settings for pump down cycles with automatic reset are also listed in the table below Lock out circuit or LP switch or series with other safety devices must be connected to CDS303 input 27 OEM need to set port 27 to coast inverse or external interlock to get rid of minimum running time restriction Electronic...

Page 39: ...efrost logic combines both advantages D e f r o s t s t a r t S t o p t h e c o m p r e s s o r 4 W a y V a l v e 4 W V s t a y s i n h e a t i n g m o d e E X V o p e n e d t o t r a n s f e r l i q u i d f r o m o u t d o o r t o i n d o o r e x c h a n g e r t h a n k s t o p r e s s u r e d i ff e r e n c e W h e n p r e s s u r e s a r e a l m o s t b a l a n c e d c h a n g e 4 W V t o c o o...

Page 40: ...ystem controller and qualified oil management Under such conditions the compressor could run below 2400rpm continually and meanwhile drive oil return management 28 10 will get by passed Oil return function To double ensure oil return from system compressor speed will boost to 3600 rpm at a fixed time intervals as programmed in parameter 28 12 default 24 hrs any way Oil management related parameter...

Page 41: ...failure Requirements Solutions VZH compressors are delivered with 100 ppm moisture level At the time of commissioning system moisture content may be up to 100 ppm During operation the filter drier must reduce this to a level between 20 and 50 ppm To achieve this requirement a properly sized and type of drier is required Important selection criteria s include driers water content capacity system re...

Page 42: ... scroll compressor is equipped with one lift ring on the top shell Always use one lift ring and discharge tube when lifting the compressor Use lifting equipment rated and certified for the weight of the compressor or compressor assembly A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution The use of lifting hooks closed with a clasp is re...

Page 43: ...ons with degreasing agent Flow nitrogen through the compressor Use flux in paste or flux coated brazing rod Use brazing rod with a minimum of 5 silver content It is recommended to use double tipped torch using acetylene to ensure a uniform heating of connection To enhance the resistance to rust a varnish on the connection is recommended Before eventual un brazing of the compressor or any system co...

Page 44: ...n each compressor at the factory between each phase and ground Carry out a dielectric strength test by short circuiting terminals L1 L2 and L3 Energize by max 1920 V DC hi pot for code G compressors and 1460 V DC hi pot for code J compressors for one second between this short circuit and the chassis and leakage current must be less than 5 mA When running dielectric strength tests of the entire ins...

Page 45: ...Correct oil level in compressor sump indicating proper oil return Low foaming in sight glass and compressor sump temperature 10K 18 F above saturation temperature to show that there is no refrigerant migration taking place Acceptable cycling rate of compressors including duration of run times A short cycling protection is provided in the CDS frequency converter It is factory preset enabled with th...

Page 46: ...ompatibility Replace relevant part Check motor current Settings Control Comp Working load map Mains Shut off reset yes no 12 13 Commercial Compressors March 2014 2 14 Earth Fault Output side Check motor cable Correct the fault Check VZH Motor resistance and isolation Reset start Check alarm Continue 16 Short circuit Output side 30 31 32 Motor phase missing 38 Internal fault Setting Error s Incompa...

Page 47: ...mp Safe stop activated Check 24V On 12 13 terminals 24V supply to terminal 37 Turn off power Reset start Check external controls Check connections Reset start 29 Check alarm Continue 65 68 direct wire Commercial Compressors March 2014 4 DC OV Check main power supply voltage DC UV Main Failure Check power supply voltage Turn off power Reset start Reset start 7 Check alarm Continue 8 36 Too high or ...

Page 48: ...utomatic restart after 30s Wrong wiring of U V W Start failed Minimum speed not reached after 2 sec Compressor stopped similar reason as A49 Automatic restart after 30s 10 restarts before blockage 20 possible 49 Check alarm Continue 18 Compressor stopped Compressor bearing wear 10 restarts before blockage 20 possible INTEGRATION INTO SYSTEM 48 AB237586440343en 000601 ...

Page 49: ... SYSTEM DESIGN INTEGRATION INTO SYSTEM ORDERING INFORMATION Dismantal and disposal Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site INTEGRATION INTO SYSTEM 49 AB237586440343en 000601 ...

Page 50: ...t Static stacking pallets mm inch mm inch mm inch kg lb VZH052 12 1170 46 1 815 32 1 650 25 6 540 1190 3 VZH065 12 1170 46 1 815 32 1 650 25 6 540 1190 3 Drive supply voltage Compressor IP20 IP55 Height Width Depth Weight Height Width Depth Weight mm inch mm inch mm inch kg lb mm inch mm inch mm inch kg lb T2 code J VZH052 065 346 13 6 810 31 9 320 12 6 24 53 346 13 6 810 31 9 320 12 6 28 62 T4 co...

Page 51: ...0 480V 3ph 50 60Hz VZH052 CDS303 11kW IP20 H2 CDS303P11KT4E20H2 135X3298 IP20 H3 CDS303P11KT4E20H3 135X3373 IP55 H2 CDS303P11KT4P55H2 135X3362 IP55 H3 CDS303P11KT4P55H3 135X3375 VZH065 CDS303 15kW IP20 H2 CDS303P15KT4E20H2 135X1998 IP20 H3 CDS303P15KT4E20H3 135X3379 IP55 H2 CDS303P15KT4P55H2 135X3369 IP55 H3 CDS303P15KT4P55H3 135X3380 T6 525 600V 3ph 50 60Hz VZH052 CDS303 15kW IP20 HX CDS303P15KT6...

Page 52: ...ltipack 6 Code n Description Application Packaging Pack size 120Z0059 Belt type crankcase heater 65 W 230V CE mark UL Wire length 1000 mm VZH052 065 Multipack 6 120Z0060 Belt type crankcase heater 65 W 400 V CE mark UL Wire length 1000 mm VZH052 065 Multipack 6 120Z5012 Belt type crankcase heater 70W 460V CE mark UL VZH052 065 Multipack 6 120Z5013 Belt type crankcase heater 70 W 575V CE mark UL VZ...

Page 53: ...tipack 10 Spare parts frequency converter Code n Description Application Packaging Pack size 120Z0326 LCP display Frequency converter all models Single pack 1 175Z0929 RS cable to LCP Frequency converter all models Single pack 1 130B0264 LCP cradle required to mount the LCP on IP55 casings Frequency converter all models Single pack 1 LCP s Oil level switch Type Code n Description Application Packa...

Page 54: ...d us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents AB237586440343en 000601 Danfoss DCS CC 2019 10 Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes http cc ...

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