Danfoss VZH Series, Application Manuallines

Page 1: ...Inverter scroll compressors VZH028 035 044 single R410A Application guidelines http cc danfoss com ...

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Page 3: ...Content VZH028 035 044 single compressors 4 3 FRCC PC 034 A2 02 Application Guidelines ...

Page 4: ...qualization connection 15 Suction discharge connections 15 Frequency converter dimensions 15 CDS803 frequency converter 16 Electrical data connections and wiring 17 Supply voltage 17 Compressor electrical specifications 17 Terminal cover mounting 17 Terminal cover removal 17 Fuses 18 Wire sizes 19 Wiring EMC protection 19 EMC correct installation of an IP20 frequency drive CDS803 20 Wiring diagram...

Page 5: ...rigeration or air conditioning system 35 Compressor sound radiation 35 Mechanical vibrations 35 Speed by pass 35 Gas pulsation 35 Installation 36 Compressor handling 36 Mounting 36 Removing connections shipping plugs 36 System cleanliness 37 Tubing 37 Filter driers 37 Brazing and soldering 37 Compressor connection 37 High voltage test 38 Leak detection 39 Vacuum pump down and moisture removal 39 R...

Page 6: ...ge valves for better efficiency at low pressure ratio Scrolls with optimized volume ratio lead to better heat pump application New distributed IPM motor lead to higher power factor Linear control oil pump PVE 32 lubricant EMC Electro Magnetic Compatibility bracket provided allows for grounding termination of shielded wire harness which reduces EMC emissions between drive and compressor 6 FRCC PC 0...

Page 7: ...d in the following pages Detailed performances can be found in datasheets and in selection programs Compressor size Different frequency converter variants are available according to 1 Mains supply voltage 2 IP class CDS803 drives are available in IP20 or IP21 requiring additional kit housings 3 RFI Radio Frequency Interference class H4 4 Printed Circuit Board PCB coated When the compressor size an...

Page 8: ... drive Equipement version A brazed connections single version B brazed connections manifold version Motor voltage code to CDS803 G 380 480V 3 50 60 Hz J 200 240V 3 50 60 Hz main supply voltage to frequency converter Oil sight glass Oil level switch Single version Threaded None Manifold version None Threaded H4 E20 T4 P7K5 803 CDS Dedicated compressor drive for VZH scroll Serie 803 output power in ...

Page 9: ...ps for 19 minutes the internal lubrication algorithm in the drive will accelerate the compressor speed to 40 rps or above for 60 seconds to ensure sufficient lubrication of compressor moving parts Warning This function is enabled by parameter 28 10 as default setting Please notice when hands on mode is selected oil return management will not work even if parameter 28 10 oil return management is se...

Page 10: ...222 1 751 15692 1 505 18484 1 146 21622 0 657 45 2891 2 799 3718 2 795 4687 2 833 5819 2 895 7137 2 965 8665 3 022 10424 3 051 12437 3 033 14727 2 95 17316 2 784 65 4760 4 349 5851 4 408 7121 4 487 8594 4 566 10289 4 628 12228 4 655 6000 100 5 6361 2 344 7977 2 398 9916 2 387 12217 2 293 14917 2 1 18055 1 792 21670 1 353 25 5069 3 157 6516 3 314 8221 3 452 10222 3 553 12557 3 601 15263 3 58 18379 ...

Page 11: ... 0 657 45 3198 2 799 4106 2 795 5168 2 833 6407 2 895 7849 2 965 9517 3 022 11436 3 051 13630 3 033 16123 2 95 18941 2 784 65 5703 4 349 6988 4 408 8483 4 487 10212 4 566 12199 4 628 14469 4 655 6000 100 5 6730 2 344 8434 2 398 10478 2 387 12900 2 293 15741 2 1 19041 1 792 22841 1 353 25 5449 3 157 6998 3 314 8821 3 452 10958 3 553 13449 3 601 16335 3 58 19655 3 473 23449 3 264 27758 2 936 32621 2...

Page 12: ... 1 884 13222 1 734 15692 1 49 18484 1 135 21622 0 65 45 2891 2 771 3718 2 767 4687 2 805 5819 2 867 7137 2 935 8665 2 993 10424 3 021 12437 3 003 14727 2 921 17316 2 757 65 4760 4 306 5851 4 365 7121 4 442 8594 4 52 10289 4 582 12228 4 609 6000 100 5 6361 2 321 7977 2 374 9916 2 363 12217 2 27 14917 2 079 18055 1 774 21670 1 339 25 5069 3 126 6516 3 282 8221 3 418 10222 3 518 12557 3 565 15263 3 5...

Page 13: ...35 23057 0 65 45 3198 2 771 4106 2 767 5168 2 805 6407 2 867 7849 2 935 9517 2 993 11436 3 021 13630 3 003 16123 2 921 18941 2 757 65 5703 4 306 6988 4 365 8483 4 442 10212 4 52 12199 4 582 14469 4 609 6000 100 5 6730 2 321 8434 2 374 10478 2 363 12900 2 27 15741 2 079 19041 1 774 22841 1 339 25 5449 3 126 6998 3 282 8821 3 418 10958 3 518 13449 3 565 16335 3 544 19655 3 438 23449 3 231 27758 2 90...

Page 14: ... 11 Nm 1 Nm Ø11 Ø164 5 Suction line 3 4 Organ pipe fitting Schrader valve and cover Overall height Top of sensor bracket 404 4 360 4 230 5 55 0 42 5 78 0 11 239 190 5 Ø19 5 4X 95 25 129 5 109 7 Suction line 111 3 discharge line 14 2 45 2 31 17 34 60 Oil level sensor prism Discharge line 1 2 Ø164 5 Top of sensor bracket Suction 3 4 Discharge line 1 2 404 4 360 4 230 5 Oil Sight Glass 1 1 8 Schrader...

Page 15: ...nd on supply voltage IP rating and power The table below gives an overview of the overall dimensions and different drive enclosures H3 H5 Details for each drive enclosure are on the following pages Sight glass oil level switch Oil equalization VZH028 035 044 Rotolock 1 1 8 Suction Discharge VZH028 035 044 3 4 1 2 Drive supply voltage Drive power kW Compressor voltage code Compressor model IP20 Dri...

Page 16: ...7 8 4 7 9 H5 IP20 334 402 314 150 120 255 12 6 7 8 5 9 5 A1 Including decoupling plate The dimensions are only for the physical units but when installing in an application it is necessary to add space for free air passage both above and below the units The amount of space for free air passage is listed in frequency converter dimensions Clearance above below mm inch 99 99 Decoupling Plate Illustrat...

Page 17: ...e is the current value at maximum load in the operating envelope and at maximum speed and maximum drive input voltage RLA Rated Load Amp Max Operating Current A Wiring connections Max operating current is the maximum continuous current which is 115 of RLA This value is printed on compressor nameplate VZH scroll compressors will only compress gas while rotating counter clockwise when viewed from th...

Page 18: ...0 JJN 60 60 PKZM4 63 3x380 480 V IP20 4 TR VZH028 FRS R 25 KTS R25 JKS 25 JJS 25 25 PKZM4 25 5 TR VZH035 FRS R 25 KTS R25 JKS 25 JJS 25 25 PKZM4 25 6 5 TR VZH044 FRS R 30 KTS R30 JKS 30 JJS 30 30 PKZM4 50 Danfoss recommends using the fuses listed below to protect service personnel and property in case of component break down in the frequency converter For circuit breakers Moeller types have been t...

Page 19: ...he metal chassis of the converter Use star washers and galvanically conductive installation plates to secure good electrical connections Refer to instructions MG18N102 for tightening torques and screw sizes Note that the CDS803 must be mounted on a plain wall to ensure a good air flow through its heat exchanger From network to frequency converter From frequency converter to compressor Type mm AWG ...

Page 20: ... 3 A Not present on all power sizes Do not connect shield to 61 01 02 03 relay1 relay2 UDC UDC Motor U V W 06 05 04 240 V AC 3 A EMC correct installation of an IP20 frequency drive CDS803 EMC qualification reports are available upon request to Danfoss technical support B a c k OK Com On Warn Alarm Hand On Reset Auto On Menu Status Quick Menu Main Menu L1 L2 L3 PE Min 16 mm Equalizing cable Control...

Page 21: ...or 4 20mA Analague Input x 55 Com Analague In Out x 12 24V output 18 External On Off NO x x 19 Digital Input 27 Safety Device e g HP LP switch x x 29 Digital Input 20 Com Digital Input 98 To Compressor T3 x x 97 To Compressor T2 x x 96 To Compressor T1 x x 99 Earth x x 03 02 01 Relay 1 06 05 04 Relay 2 69 68 RS485 Bus 61 RS485 Bus Com Optional connection X Mandatory connection The CDS803 frequency...

Page 22: ...ains connection to the CDS803 frequency converter order has no influence on the output phase sequence which is managed by the frequency converter The compressor terminal box IP rating according to IEC529 is IP22 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 loc...

Page 23: ...e maximum allowable voltage imbalance between each phase is 3 Voltage imbalance causes high amperage over one or several phases which in turn leads to overheating and possible drive damage Mains imbalance function in CDS803 frequency converter can be set to 0 Trip or 1 Warning in 14 12 parameter It is by default factory preset to 1 Warning Then the compressor electrical motor is never affected by ...

Page 24: ...2 or CE 0038 European Directive All VZH models UL Underwriters Laboratories All VZH models EMC 2004 108 EC All VZH models CCC All VZH models Products Internal free volume at LP side without oil liter VZH028 3 2 VZH035 3 2 VZH044 3 2 Products VZH028 VZH035 VZH044 Fluids Group 2 Category PED I TS service temperature LP 35 C TS 55 C PS service pressure LP 33 3 bar g 24 FRCC PC 034 A2 02 Application G...

Page 25: ...ly controlled by an external main controller it is recommended to limit the start stop frequency to 12 times per hour The operating envelopes for VZH scroll compressors are given in the figures below where the condensing and evaporating temperatures represent the range for steady state operation Under transient conditions such as start up and defrost the compressor may operate outside this envelop...

Page 26: ...ge temperature must be monitored during development test by the equipment manufacturer The compressor must not be allowed to cycle on the discharge gas thermostat Continuous operations beyond the compressor s operating range will cause serious damage to the compressor VZH028 044 can install a discharge sensor dome sensor at the top of shell through a bracket and the sensor has to been connected an...

Page 27: ...rication compressor speed will boost to 40 rps minimum ORM Boost Speed 28 17 at a fixed time intervals as programmed in parameter 28 12 default 24 hrs any way OEM could set 28 17 to a higher speed such as 70 rps to secure oil management According to different application requirements OEM can either add oil separator including to add more oil in the system or adjust oil return parameters or might n...

Page 28: ...circuit 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 The lock out circuit or LP switch or series with other safety devices could be connected to CDS803 input 27 The low pressure switch must have the highest priority that shall not be by passed It means when low pressure...

Page 29: ...ning back to the compressor when stopped For Inverter applications with long lines we recommend the use of an oil separator even if it is only the condenser which is far away from the unit Piping must also be designed with care in order to make sure the remaining oil not trapped by the oil separator is properly carried over the system Basic principal is shown here Note that for the discharge line ...

Page 30: ... positive effect of sub cooling on system efficiency will be significantly larger than in R22 R407C systems Furthermore for good operation of the expansion device and to maintain good efficiency in the evaporator it is important to have an adequate liquid sub cooling Without adequate sub cooling flash gas will be formed at the expansion device resulting in a high degree of vapor at the evaporator ...

Page 31: ...than 2 3 bar An external non return valve is recommended to avoid liquid flood back from the high pressure side Liquid receiver Refrigerant charge optimization varies with compressor speed To avoid flash gas at low speed a receiver may be necessary Receiver dimensioning requires special attention The receiver shall be large enough to contain part of the system refrigerant charge but shall not be t...

Page 32: ...ng pressure must be set at the minimum saturated condensing temperature shown in the application envelopes Under very low ambient conditions in which testing has revealed that the above procedures might not ensure satisfactory condensing and suction pressures the use of a liquid receiver with condenser and receiver pressure regulators would be possible Condensing pressure control is also strongly ...

Page 33: ... 1 meter of discharge line is necessary to generate this volume To help reduce the gas volume immediately after start up even further the supply of cooling water to the heat exchanger may be opened before the compressor starts up so as to remove superheat and condense the incoming discharge gas more quickly Because of the large compressor capacity variation and VZH capability to run at low condens...

Page 34: ...me compressor will run at 50 rps for at least 1 minute Thus to avoid excessive liquid refrigerant to come back to the compressor sump The use of a suction line accumulator is strongly recommended in reversible cycle applications This because of the possibility of a substantial quantity of liquid refrigerant remaining in the evaporator which acts as a condenser during the heating cycle This liquid ...

Page 35: ...must be checked frame piping pipes using cushioned clamps But if some frequencies continue to produce unacceptable vibration levels speed by pass is adjustable in the frequency converter in order to avoid some frequency ranges Four by pass ranges are adjustable and settings can be made in parameter group 4 6 The VZH scroll compressor has been designed and tested to ensure that gas pulsation has be...

Page 36: ... concerning lifting objects of the type and weight of these compressors Maintain the compressor in an upright position during all handling operations When the compressor is mounted as part of an installation never use the lift rings on the compressor to lift the installation The risk is that the lugs could separate from the compressor or that the compressor could separate from the base frame with ...

Page 37: ... When brazing the compressor fittings do not overheat the compressor shell which could severely damage certain internal components due to excessive heating Use of a heat shield and or a heat absorbent compound is highly recommended Due to the relatively sizable tubing and fitting diameters a double tipped torch using acetylene is recommended for brazing operation on VZH compressors B C A heat shie...

Page 38: ...and can cause substantial damage to the internal parts of the system and compressor The polyolester oil used in VZH compressors is highly hygroscopic and will rapidly absorb moisture from the air The compressor must therefore not be left open to the atmosphere for a long period of time The compressor fitting plugs shall be removed just before brazing the compressor The compressor should always be ...

Page 39: ...s on the liquid line between the condenser outlet and the filter drier Then during commissioning when needed a complement of charge can be done in liquid phase slowly throttling liquid in on the low pressure side as far away as possible from the compressor suction connection The refrigerant charge quantity must be suitable for both summer and winter operations Refer to news bulletin FRCC EN 050 Da...

Page 40: ...am filling in the sight glass indicates large concentration of refrigerant in the oil and or presence of liquid returning to the compressor The oil level can also be checked a few minutes after the compressor stops the level must be between and of sight glass When the compressor is off the level in the sight glass can be influenced by the presence of refrigerant in the oil Always use original Danf...

Page 41: ...Single compressors Trouble shooting 06 03 2015 page 1 c a s s w c w m s 06 03 2015 page 2 f S mains O e b s a c l o Check HP LP switch Reset start 41 FRCC PC 034 A2 02 Application Guidelines ...

Page 42: ...Single compressors Trouble shooting 06 03 2015 page 3 heating t o m overheating r 06 03 2015 page 4 42 FRCC PC 034 A2 02 Application Guidelines ...

Page 43: ...Single compressors Trouble shooting 06 03 2015 page 5 43 FRCC PC 034 A2 02 Application Guidelines ...

Page 44: ...MA 120G0067 VZH044CJAMA 120G0068 Manifold VZH044CGBMA VZH044CJBMA The tables on the following pages give code numbers for ordering purposes for the VZH compressor and CDS803 frequency converter kit packed and shipped separately VZH scroll compressors and drive can be ordered in single packs Please use the code numbers from below tables for ordering Kit ordering and shipping Compressor single pack ...

Page 45: ...NO T2 200 240V 3ph 50 60Hz VZH028 CDS803P6K0T2E20H4 134N4260 VZH035 CDS803P7K5T2E20H4 134N4261 VZH044 CDS803P10KT2E20H4 134L9470 T4 380 480V 3ph 50 60Hz VZH028 CDS803P6K0T4E20H4 134N4262 VZH035 CDS803P7K5T4E20H4 134N4263 VZH044 CDS803P10KT4E20H4 134L9473 LCP user interface 120Z0581 accessory 45 FRCC PC 034 A2 02 Application Guidelines ...

Page 46: ...6 Solder sleeve adapter set 1 1 4 Rotolock 3 4 ODF 1 Rotolock 1 2 ODF VZH028 044 Multipack 6 Solder sleeve adapter sets Type Code n Description Application Packaging Pack size 120Z5040 Belt type crankcase heater 65W 230V CE mark UL wire length 1270mm VZH028 044 Multipack 4 120Z5041 Belt type crankcase heater 55 70W 400 460V CE mark UL wire length 1270mm Multipack 4 Type Code n Description Applicat...

Page 47: ...r VZH028 044 Multipack 10 Spare parts frequency converter Type Code n Description Application Packaging Pack size 120Z0581 LCP Frequency converter all models Single pack 1 120Z0617 LCP kit for remote mounting Frequency converter all models Single pack 1 Frame Compressor Decoupling plate Packaging Pack size 200 240V 380 480V H3 VZH028 035 120Z0582 Single pack 1 H4 VZH028 035 VZH044 120Z0583 Single ...

Page 48: ...and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents FRCC PC 034 A2 02 Danfoss DCS CC 2015 05 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 h...