Danfoss VZH088CGANA Inverter compressors for Air Conditioning Instructions

Danfoss VZH088CGANA Inverter compressors for Air Conditioning

Specifications

• Model Number: VZH088CGANA
• Serial Number: GM2500000001
• Refrigerant: R410A
• Supply Voltage: 380-480V 3~50-60 Hz
• Service Pressure: 33.3 bar (LP Side), 45 bar (HP Side)
• Lubricant Type: P.O.E. 160SZ
• Compressor Frequency: 50-200 Hz
• Max Rated Current: 35.2A
• Speed Range: 25-100 reps
• Volume: 12.7 L (Oil Level Monitor), 0.7 L (ManifoldVersion)

Product Usage Instructions

Oil Injection Control Assembly

• Place the clip-on coil with the gasket over the valve body on the compressor.
• Attach the connector to the coil using the delivered accessories and wire it to the CDS relay location.

Oil Injection Control Dismantling
To dismantle the oil injection control, simply remove the clip-on coil by using a screwdriver.

Oil Level Sensor Assembly

Basic connections:

• Ensure correct wiring between compressor terminals T1, T2, T3, and frequency converter terminals 96, 97, 98. – Shield the compressor motor cable and ground the armored part on both cable ends.
• Use an EMC cable gland for installation and grounding.
• Install a low-pressure safety switch to prevent vacuum operation.
• Verify the compressor rotation direction and pumping action during start-up.

Instructions

VZH088°117°170 Compressor

• A: Model number
• B: Serial number
• C: Refrigerant
• D: Supply voltage to frequency converter
• E: Housing service pressure
• F: Factory-charged lubricant
• G: Compressor frequency Max Rated Current (VZH088/117/170CGN)
  • Compressor frequency Max Rated Current (VZH088/117/170**M)
  • Compressor frequency & Max Must Trip Current (VZH088/117/170**N)
  • Compressor frequency & Max Operating Current (VZH088/117/170**M)

VZH088/117/170 A & B Operating map – R410A

• The compressor must only be used for its designed purpose(s) and within its scope of application (refer to «operating limits»). Consult Application guidelines and datasheet available from http://cc.danfoss.com
• Under all circumstances, the EN378 (or other applicable local safety regulation) requirements must be fulfilled.
• The compressor is delivered under nitrogen gas pressure (between 0.3 and 0.7 bar) and hence cannot be connected as is; refer to the «assembly» section for further details.
• The compressor must be handled with caution in the vertical position (maximum offset from the vertical: 15°)

Oil injection control assembly

Put the clip-on coil (1) with the gasket (2) over the valve body (3) on the compressor

Attach the connector (4) to the coil using the delivered accessories (5) and (6).

Wire the connector as indicated and plug it to the CDS relay 1 location.
Oil injection control dismantling

Remove the clip-on coil by using a screwdriver.

Oil level sensor 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

VZH088/117/ 170 C Operating Map – R410A/R452B/R454B

• For VZH088/117 with R410A/R452B/R454B and VZH170 with R410A, the solid line envelope is valid for a suction superheat within 5K at nominal voltage. Higher suction superheat may lead to discharge temperatures above 135°;
• For superheat between 5K and 11K, this top left envelope might be reduced by the condensing temperature of 1°C or 2°C to keep discharge T° below 135°C.
• For superheat above 11K, the envelope will further be reduced based on 135°C discharge temperature restriction.
• For VZH170 with R452B/R454B, The solid line envelope is valid for suction to superheat within 5K at nominal voltage. Higher suction superheat may lead to discharge temperatures above 150°;
• For superheat between 5K and 11K, this top left envelope might be reduced by the condensing temperature of 1°C or 2°C to keep discharge T° below 150°C.
• For superheat above 11K, the envelope will further be reduced based on 150°C discharge temperature restriction.

Basic connections

• Depending on the frequency converter version, the physical position of individual connectors may differ from the below diagram.
• Always make sure that the compressor terminals T1, T2, T3 are connected to the frequency converter terminals 96, 97, and 98 respectively.
• The compressor motor cable must be shielded and the armored part must be connected to the 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.

• – : Optional connection
• X : Mandatory connection

The CDS303 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: 0 – 10 V control, Frequency converter in slave mode
• Process loop: 4 – 20 mA control, Frequency converter under own PID controller

Check carefully for compatibility between the compressor model and variable speed drive.
Basic connections refer to application guidelines or contact with Danfoss regional technical support.

Electrical connections / Wiring for Oil level sensor
See at the correct diagram corresponding to different power supply models for proper wiring

Introduction
These instructions pertain to the VZH Variable Speed scroll compressors used for A/C systems. They provide necessary information regarding safety and proper usage of this product.

Handling and storage

• Handle the compressor with care. Use the dedicated handles in the packaging. Use the com-pressor lifting lug and use appropriate and safe lifting equipment.
• Store and transport the compressor in an upright position.
• Store the compressor between -35 °C(-31 °F) and 70 °C(158 °F) when charged with nitrogen.
• Don’t expose the compressor and the packaging to rain or corrosive atmosphere.

Safety measures before assembly

CAUTION: Never use the compressor in a flammable atmosphere.

• The compressor ambient temperature may not exceed the Ts max value for the LP side indicated on the compressor nameplate during the off-cycle.
• Mount the compressor on a horizontal flat surface with less than 3° slope.
• The compressor can only be supplied by a frequency converter. Make sure that the frequency converter is the dedicated one for the compressor (power size and voltage: input & output). Parameter 1.13 of the frequency converter lists the possible combinations of compressors, frequency converters, and refrigerants.
• When installing a VZH, use equipment specifically reserved for HFC refrigerants which was never used for CFC 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.
• Make sure the installation is equipped with high-pressure safety components (e.g. pressure switch, pressure relief valve) to prevent the bursting of pressure-containing components.

Assembly

• Slowly release the nitrogen holding charge through the schrader port.
• 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. When the schrader port is used for this, remove the internal valve.

Leak detection

WARNING: Never pressurize the circuit with oxygen or dry air. This could cause fire or explosion.

• Do not use dye for leak detection.
• Perform a leak detection test on the complete system.
• The test pressure must not exceed 1.1 x PS value for the LP side and PS value for the HP side indicated on the compressor nameplate.
• When a leak is discovered, repair the leak and repeat the leak detection.

Vacuum dehydration

• Never use the compressor to evacuate the system.
• Connect a vacuum pump to both the LP & HP sides.
• Evacuate the system to a pressure of 500 µm Hg (0.67 mbar) absolute.
• Do not use a megohmmeter nor apply power to the compressor while it is under vacuum as this may cause internal damage.

Electrical connections

• Switch off and isolate the main power supply. See the previous page for wiring details.
• The compressor is protected against excess current by the frequency converter. Follow local regulations regarding power line protection. The compressor must be connected to the ground.
• All electrical components must be selected as per local standards and compressor requirements.
• Please refer to the 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.
• Follow very closely the installation instructions for the frequency converter:
• 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 screened design. The cable for the 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 in 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 according to Danfoss’s recommendations for the CDS frequency converter and VZH variable speed compressor.

Filling the system
Fill the refrigerant in the liquid phase into the outlet side of the condenser or liquid receiver. The charge must be as close as possible to the nominal system charge to avoid low-pressure opera-tion and excessive superheat.

Never let the pressure on the LP side exceed the pressure on the HP side with more than 5 bar. Such pres-sure difference could cause internal compressor damage.

• Keep the refrigerant charge below the indicated charge limits if possible. Above this limit protect the compressor against the risk of flooded start (see Application Guidelines section “manage off cycle migration”).

Verification before commissioning

WARNING: Use safety devices such as safety pressure switches and mechanical relief valves 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 and relief valves don’t exceed the maximum service pressure of any system component.

• A low-pressure switch is mandatory to avoid vacuum operation. Minimum setting 1.5 bar (g).
• Verify that all electrical connections are properly fastened and in compliance with local regulations.
• The crankcase heater function is factory preset to «disabled». It must not be used for VZH170 but could be used for VZH088/117. In the default case, an external crankcase heater is required.
• After commissioning it is strongly recommended to keep the frequency converter always energized.

Start-up

• All service valves must be in the open position.
• Balance the HP/LP pressure.
• Energize the compressor. It must start promptly.
• If the compressor doesn’t start, verify that the compressor is hooked up to the frequency converter; check the power lead connections. If these verifications reveal no abnormality, check the motor windings with an ohmmeter.
• 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 the 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 super-heat is 30K.

Check with the running compressor

• Check current draw and voltage.
• Check suction superheat to reduce the risk of slugging.
• Observe the oil level at the 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 sys-tem 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 mini-mum gas velocity.
  • a good oil management at high speed with maximum oil carryover.
• Respect the operating limits.
• Check all tubes for abnormal vibration. Movements over 1.5 mm require corrective measures such as tube brackets.
• When needed, additional refrigerant in the liquid phase may be added to 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 into the atmosphere.
• Before leaving the installation site, carry out a general installation inspection regarding cleanliness, noise, and leak detection.
• Record the 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 have 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 measuring the return gas superheat and compressor sump temperature. The sump should be at least 8K for VZH088/117 and 6K for VZH170 above the saturated suction tempera-ture under steady-state operating conditions.
• The high-pressure switch trips out: Check con-denser 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 non-condensable (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 about the refrigerant pressure tables (pressure-temperature), the super-heat and the sub-cooling, etc. (if an additional charge is deemed necessary, refer to section 8).
  • Compressor short cycling: The number of cycles shall never exceed 12 starts per hour.

Maintenance

WARNING: Internal pressure and surface temperature are dangerous and may cause permanent injury. Maintenance operators and installers require appropriate skills and tools. Tubing and compress upper shell 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, the 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.
• 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.
• Check the internal temperature of the frequency converter on its display and the cooling air below.
• Faults are logged in the frequency converter memory and can be displayed. This can help to evaluate and improve the parameters of the frequency converter or of the system itself.

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.

The product warranty may be void in the 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 about installation, application, or maintenance.
• Use in mobile applications.
• Use in the explosive atmospheric environment.
• No model number or serial number was transmitted with the warranty claim.

Disposal
Danfoss recommends that compressors, frequency converters, and compressor oil should be recycled by a suitable company.

Danfoss A/S
Climate Solutions
danfoss.com
+45 7488 2222

Any information, including, but not limited to information on the selection of the product, its application or use, product design, weight, dimensions, capacity, or any other technical data in product manuals catalogs descriptions, advertisements, etc., and whether made available in writing, orally, electronically, online or via download, shall be considered informative and is only binding if and to the Dates reserve the right to eat its protasis without notice. This applies to products purchased but not levered provided ons such literati ors canes made without changes to form, fit, or function of the product. All trademarks in this material are property of Danfoss A/S or Danfoss group companies. Danfoss and the Danfoss logo are trademarks of Danfoss A/S. All rights reserved.

FAQ

Frequently Asked Questions

• Q: What is the recommended refrigerant for this compressor?
  • A: The recommended refrigerant is R410A.
• Q: What is the voltage requirement for the compressor?
  • A: The supply voltage required is 380-480V at 3~50-60 Hz.
• Q: How should I wire the oil injection control valve?
  • A: Place the clip-on coil with gasket over the valve body on the compressor, attach the connector, and wire it to the CDS relay as indicated.

AN067486434011en-000501 – 8510267P01AC
© Danfoss | Climate Solutions | 2023.04

References

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