Danfoss VZN086-104-140-175 Compressor Instructions

Danfoss VZN086-104-140-175 Compressor

Specifications

• Model Number: VZN104AGANA
• Manufactured in: China
• Serial Number: PH2500000002
• Power Supply: 380-480V, 3-phase, 50Hz & 60Hz
• Refrigerant: R290
• Lubricant: P.O.E. 160SZ
• Frequency Range: 90-420 Hz
• Speed Range: 30-140 reps
• Max Operating Current: 32 A

Product Usage Instructions

Basic Connections

• Ensure compressor terminals T1, T2, and T3 are connected to frequency converter terminals U, V, and W respectively.
• Compressor motor cable must be shielded with the armored part connected to the ground on both ends.
• Use a low-pressure safety switch to prevent compressor vacuum operation.
• Verify compressor rotation direction and pumping action during start-up.

Power Connections

For 230V single-phase variants:

• L1 – Supply L1
• N – Neutral
• E – Power earth/ground

For 400V 3-phase variants:

• L1 – Supply L1
• L2 – Supply L2
• L3 – Supply L3
• E – Power earth/ground
• U – Motor phase
• V – Motor phase
• W – Motor W phase

Safety Guidelines

• Operate the compressor within the scope of safety regulations and EN378 standards.
• Consult application guidelines and datasheets for specific details.
• The compressor must be handled vertically and with caution due to nitrogen gas pressure.
• The compressor must be used only for its designed purpose.

FAQ

Q: What is the recommended length for the motor cable?

A: The maximum permitted motor cable length for all models is 10 meters shielded or 20 meters unshielded.

Q: How should the compressor motor cable be connected?

A: 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 the side of the frequency converter.

OVERVIEW

• 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 Operating Current

Operating maps

• The envelope left area (Evaporating temperature below 5°C) is valid for min suction superheat 5K(9°F), the right area (Evaporating temperature above 10°C) is valid for min suction superheat 10K(18°F), between area min suction superheat can be controlled between 5K(9°F) and 10K(18°F).
• Higher suction superheat may lead to a discharge temperature above 150°C for VZN with R290.
• Moreover, the discharge gas temperature must not exceed 150°C for VZN.
• The Operating envelope data for VZN guarantees reliable operations of the compressor for steady-state operation.

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, and T3 are connected to the frequency converter terminals U, V, and W 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 the side of the frequency converter.
• 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.
• 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 regulations) 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°)

Instructions

Motor connection

• The drive inherently produces fast switching of the output voltage (PWM) to the motor compared to the mains supply, for motors that have been wound for operation with a variable speed drive then there are no preventative measures required, however, if the quality of insulation is unknown then the motor manufacturer should be consulted and preventative measures may be required.
• The motor should be connected to the CDS 203 U, V, and W terminals using a suitable 3 or 4-core cable. Where a 3-core cable is utilized, with the shield operating as an earth conductor, the shield must have a cross-sectional area at least equal to the phase conductors when they are made from the same material. Where a 4-core cable is utilized, the earth conductor must be of at least equal cross-sectional area and manufactured from the same material as the phase conductors.
• The motor earth must be connected to one of the CDS 203 earth terminals.
• Maximum permitted motor cable length for all models: 10 meters shielded, 20 meters unshielded.

Power connections

Control wiring

The CDS 203 has pluggable control terminals to support easy installation.

There are three pluggable control terminal blocks split into:

• Serial Communications (T1-T3)
• Inputs (T5 – T9)
• Output Relay (T10 – T11)

RJ45 port

• This port is intended for connection to a PC running Cool Setting configuration software or to connect the drive to a system controller using Modbus RTU

warning:

• This is not an Ethernet connection. Do not connect directly to an Ethernet port.
• The RJ45 port has some terminals that are internally connected in parallel with the pluggable control terminals as shown below.

Safe torque off

Safe Torque OFF will be referred to as “STO” through the remainder of this section. If the “STO” function is not required in your installation, you must link out the “STO” circuit by linking terminal 4 to terminal 8 and linking terminal 7 to terminal 9 as shown in the figure below. Please read the remainder of this chapter for further information about the functionality and limitations of the “STO” circuit.

Showing the links needed if the STO is not required:

Introduction

These instructions pertain to the VZN086-104-140-175 Variable Speed scroll compressors used for A/C and HP systems. 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 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 a corrosive atmosphere.

Safety measures before assembly

• 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 a 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).
• When installing a VZN, use equipment specifically reserved for R290 refrigerants which was never used for HFC/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

• 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 connec-tions 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 per Danfoss’s recommendations for the CDS203 frequency converter and VZN086-104- 140-175 variable speed compressor.

Filling the system

• Keep the compressor switched off.
• 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 pressure 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

• Use safety devices such as safety pressure switch and mechanical relief valve in compliance with both generally and locally applicable regula-tions 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 0.5 bar (g).
• Verify that all electrical connections are properly fas-tened and in compliance with local regulations.
• In the default case, an external crankcase heater is required. The crankcase heater function is factory preset to «disabled». It must be used for VZN086-104-140-175.
• 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 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 frequen-cy converter control panel.

• The optimum compressor suction superheat according to the map superheat requirement. 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 employing measuring the return gas superheat and compressor sump temperature. The oil sump superheat should be above the low limit under steady-state operating condi-tions. For low limit see VZN Application Guideline (AB478735922007en).
• 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 with 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.
• Discharge temperature protection: For VZN086- 104- 140-175 with R290, the discharge gas tem-perature protection should be open at a maximum discharge temperature of 150°C (302°F)

Maintenance

• Internal pressure and surface temperature are dangerous and may cause permanent injury. Maintenance operators and installers require appropriate skills and tools.
• Tubing and compressing 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 frequen-cy converter on its display and the cooling air flow.
• 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 of 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

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References

• Read more on our commercial compressors | Danfoss | Danfoss

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