Danfoss VZH028, VZH065 Inverter Compressors Instructions

Danfoss VZH028, VZH065 Inverter Compressors

Specifications

• Model: VZH028-VZH065
• Electrical Ratings: 380-480V3~50/60 Hz UL
• Refrigerants: R410A/R454B/R452B
• Lubricant: RL46HB/1.41 L
• Frequency Range: 30-200 Hz
• Speed Range: 15-100 rps
• Operating Limits: -40°C to 100°C

Product Usage Instructions

• Ensure the inverter compressor is mounted securely in a well-ventilated area with proper clearance for maintenance.
• Connect the inverter compressor to a power source within the specified electrical ratings (380-480V3~50/60 Hz UL).
• Use only the approved refrigerants (R410A/R454B/R452B) and ensure proper filling according to manufacturer guidelines.
• Check and maintain the lubricant level (RL46HB/1.41 L) as recommended by the manufacturer.
• Set the frequency within the range of 30-200 Hz and adjust the speed between 15-100 rps based on your cooling requirements.
• Observe all safety precautions mentioned in the manual while operating the inverter compressor.

AQ

• Q: What should I do if the inverter compressor exceeds the operating limits?
• A: If the inverter compressor exceeds the specified operating limits, immediately shut it down and consult a professional for inspection and maintenance.
• Q: Can I use a different lubricant than RL46HB?
• A: It is recommended to use the specified lubricant (RL46HB/1.41 L) to ensure optimal performance and longevity of the inverter compressor.

MODELS

1. Model number
2. Serial number
3. Refrigerant
4. Manufacturing year
5. Supply voltage
6. Lubricant
7. PED information
8. MOC & MRC

Operating limits

All the above limits, temperatures, and speeds are secured by parameters in the drive and application controller software.
Note: For VZH028-044, 380V map difference was at right top area, max speed 5700rpm; For VZH052-065, R410A map solid line boundaries: SH=5K, dash line boundaries: need ensure Tdis<135°C.

Installation and servicing of the compressor by qualified personnel only. Follow these instructions and sound refrigeration engineering practices relating to installation, commissioning, maintenance, and service.

• 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 cc.danfoss.com.
• Never operate the compressor without the terminal box cover in place and secured.
• Under all circumstances, the EN378 (or other applicable local safety regulation) requirements must be fulfilled. Wear protective goggles and work gloves.
• The compressor must be handled with caution in the vertical position (maximum offset from the vertical : 15°).
• The compressor is delivered under nitrogen gas pressure (between 0.3 and 0.4 bar / 4 and 6 psi). Do not disassemble bolts, plugs, fittings, etc… unless all pressure has been relieved from the compressor.

Instructions

Electrical connections

VZH028 – VZH065 compressors can be powered by the dedicated variable speed drive

• When the Danfoss drive is selected, check carefully for compatibility between the compressor model and variable speed drive.

Note

1. VZH052/065-G with CDS803 only for EU market.
2. These instructions replace instructions in the grommet kit.

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, 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.

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 an optical part. Make sure the cable outlet downside vertically.
• For LC-PR, make sure the cable outlet is 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

1. Power supply (L or 24V)
2. Output NO CONTACT
3. Power supply (N or 0V)
4. Output COMMON

Introduction

• These instructions pertain to the VZH028- VZH065 variable scroll compressors used for air conditioning and reversible heat pump systems in residential applications.
• They provide necessary information regarding the safety and proper usage of this product.

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.

Safety measures before assembly

• Never use the compressor in an ammable atmosphere.
• The compressor ambient temperature may not exceed 50°C during off-cycle.
• Mount the compressor on a horizontal at 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 fiexible in 3 dimensions to dampen vibrations.
• The compressor must always be mounted using the rubber grommets supplied with the compressor.

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 techniques and vent piping with nitrogen gas flow.
• Connect the required safety and control devices.

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:

41.6 bar for

VZH028-065CDM

Maximum pressure difference between the high side and low side of the compressor| 36 bar

• 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.
• 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.

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 the 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 the compressor and drive U, V, W must match. 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.
• 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 on the 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 per Danfoss’s recommendations for the CDS frequency converter and VZH variable speed compressor.
• Refer to the variable speed drive manual for electrical connection details and installation.
• Compressor motor protection is provided by the variable speed drive.

Filling the system

• Keep the compressor switched off.
• Fill the refrigerant in the liquid phase into the outlet of the condenser or the liquid receiver. The charge must be as close as possible to the nominal system charge to avoid low-pressure operation and excessive superheating. 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 1.5bar(g) for VZH028-044 with R410A and 1.3bar(g) for VZH028-044 with R454B_R452B/1.8bar(g) for VZH052-065 with R410A and 1.6bar(g) for VZH052-065 with R454B_R452B. or a suction line accumulator.
• Never leave the filling cylinder connected to the circuit.

Verification before commissioning

• 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 do not exceed the maximum service pressure of any system component.
• A low-pressure switch is mandatory to avoid vacuum operation. Minimum setting 1.3bar(g) for VZH028-044 with R410A refrigerant, Minimum pressure 1.1bar(g) for VZH028- 044 with R452B-R454B. Minimum pressure 1.6bar(g) for VZH052-065 with R410A , 1.4bar(g) for VZH052-065 with R454B/R452B.
• Verify that all electrical connections are properly fastened and in compliance with local regulations.
• When using the 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 commissioning it is strongly recommended to keep the frequency converter always energized.

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 the compressor are open if installed.
• Energize the drive. The compressor must start, according to the NED 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 5K. The maximum allowed superheat is 30K.
• Eventual reverse rotation can be detected by the following phenomena; the excessive noise, no pressure diagonal between suction and discharge, and line warming rather than immediate cooling. A service technician should be present at initial start-up to verify that the wiring from the drive to the compressor is properly phased and that the compressor is rotating in the correct direction.
• Note that a 300-second 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.

Check with the 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 carryover.
• Respect the operating limits.
• Check all tubes for abnormal vibration. Movements over 1.5 mm / 0.06 inch require corrective measures such as tube brackets.
• When needed, additional refrigerant in the 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 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 has been opened. Also, check that all solenoid valves are in their proper position.
• Abnormal running noise: Ensure the absence of any liquid fiodor back to the compressor by measuring the return gas superheat and compressor sump temperature. The sump should be at least 8K 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.), and refrigerant charge.
• Low refrigerant charge: The correct refrigerant charge is given by the liquid sight glass indication, the condenser delta Concerning the refrigerant pressure tables (pressure-temperature), the superheat and the subcooling, 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

• 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 the system and oil should be checked regularly.

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 o the power.
• Variable speed drive model and serial number must also be transmitted with the claim.
• 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 on 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 and compressor oil should be recycled by a suitable company at its site.

CONTACT

• 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, catalog 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 extent, explicit reference is made in a quotation or order confirmation. Danfoss cannot accept any responsibility for possible errors in catalogs, brochures, videos, and other material. Danfoss reserves the right to alter its products without notice. This also applies to products ordered but not delivered provided that such alterations can be made without changes to the 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.

References

• Read more on our commercial compressors | Danfoss | Danfoss

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