Danfoss IPS 8 User guide
User Guide
Intelligent Purging System (IPS 8)
Ammonia
230 V AC, 60 Hz
Info for UK customers only
Danfoss Ltd. Oxford Road, UB9
4LH Denham, UK
Other IPS 8 User Guide languages
ir.danfoss.com
ir.danfoss.com148R9653
User Guide | Intelligent Purging System (IPS 8) Ammonia
Contents
Legal notice ...................................................................................................................................................................................................................3
Technical data ..............................................................................................................................................................................................................4
Ordering ..........................................................................................................................................................................................................................4
Introduction ..................................................................................................................................................................................................................5
Features ...........................................................................................................................................................................................................................5
Working principle .....................................................................................................................................................................................................6
Working cycle ..............................................................................................................................................................................................................7
Air traps ............................................................................................................................................................................................................................8
Connection locations ..............................................................................................................................................................................................9
Connection points ................................................................................................................................................................................................. 11
Installation ..................................................................................................................................................................................................................12
Electrical wiring ...................................................................................................................................................................................................... 14
Light Indicators ........................................................................................................................................................................................................ 16
Quick Startup ............................................................................................................................................................................................................ 17
General display.........................................................................................................................................................................................................17
Configuring using the LCD ...............................................................................................................................................................................18
Modbus RTU .............................................................................................................................................................................................................. 20
Maintenance/Service/Disposal ......................................................................................................................................................................27
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User Guide | Intelligent Purging System (IPS 8) Ammonia
Legal notice This product information is a part of the documentation for the Danfoss scope of delivery and serves
as product presentation and customer advisory service. It contains important information and
technical data regarding the product.
This product information should be supplemented with the information about the industrial safety
and health related regulations at the site of installation of the product. The regulations vary from
place to place as a result of the statutory regulations applicable at the site of installation and are
therefore not considered in this product information.
In addition to this product information and the accident prevention regulations applicable for the
respective country and area where the product is used, the technical regulations for safe and
professional work must also be observed.
This product information has been written in good faith. However, Danfoss cannot be held responsible
for any errors that this document may contain or for their consequences.
Danfoss reserves the right to make technical changes during the course of further development of the
equipment covered by this product information.
Illustrations and drawings in this product information are simplified representations. As a result of
the improvements and changes, it is possible that the illustrations do not exactly match the current
development status. The technical data and dimensions are subject to change. No claims will be
accepted on the basis of them.
Danfoss A/S
6430 Nordborg
Denmark
CVR nr.: 20 16 57 15
Telephone: +45 7488 2222
Fax: +45 7449 0949
EU DECLARATION OF CONFORMITY
declares under our sole responsibility that the
Product category: Intelligent Purger System (Air Purger)
Type designation(s): IPS 8
Covered by this declaration is in conformity with the following directive(s), standard(s) or other normative
document(s), provided that the product is used in accordance with our instructions.
Machine Directive 2006/42/EC
EN 378-2:2016 Refrigerating systems and heat pumps - Safety and environmental requirements - Part 2: Design,
construction, testing, marking and documentation
IEC 60204-1:2018 Safety requirements for electrical equipment for measurement, control and laboratory use - Part 1:
General requirements
Pressure Equipment Directive 2014/68/EU (PED)
EN 378-2:2016 Refrigerating systems and heat pumps - Safety and environmental requirements - Part 2: Design,
construction, testing, marking and documentation
Ammonia side (R717): Category A4P3. Fluid group: 1. PS = 40 bar. TS: -40 C to 60 C
R452A side: Category 1. Fluid group: 2. PS = 28 bar. TS: -40 C to 60 C
Ambient temperature: -10 C to 43 C
Electromagnetic Compatibility Directive 2014/30/EU (EMC)
IEC 61000-6-2 Electromagnetic compatibility (EMC) - Part 6-2: Generic standards - Immunity standard for industrial
environments (IEC77/488/CDV:2015)
EN 61000-6-4 Electromagnetic compatibiliy (EMC) - Part 6-4: Generic standards - Emission standard for industrial
environments
Note: EMC test performed with cable length < 30m.
Date: YYYY.MM.DD
Place of issue:
Signature:
Danfoss only vouches for the correctness of the English version of this declaration. In the event of the declaration being translated into any other
language, the translator concerned shall be liable for the correctness of the translation
ID No: 084R9456
This doc. is managed by 500B0577
Issued by
Name: Su Cheong Ho
Title: Lead Design Engineer
Refrigeration & Air Conditioning Controls
Revision No: AA
Danfoss A/S
Date: YYYY.MM.DD
Place of issue:
Signature:
Approved by
Name: Behzad Parastar
Title: Product Manager
Page
1 of
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User Guide | Intelligent Purging System (IPS 8) Ammonia
Technical data
Ordering
Supply voltage 230V AC, 1ph, 60Hz
Current 5.7 A (max. 6.5 A)
Power consumption max. 1.3 kW
Short-circuit current rating Icc 10kA
Temperature range ambient -10 °C to +43 °C (14 °F to 109 °F)
Temperature range transport/storage -30 °C to +60 °C (-22 °F to 140 °F)
Enclosure IP55
Weight max. 100 kg (221 lbs)
Dimensions (LxWxH) 1051 x 441 x 703 mm (41.4 x 17.4 x 27.7 inches)
Purger refrigerant R452A 900 gram (31.7 oz)
Max. operating pressure (PS) R452A 28 bar (406 psi)
System refrigerant R717
Min. operating pressure R717 6.5 bar (94 psi)
Max. operating pressure R717 40 bar (580 psi)
Operating temperature R717 -40 °C to +60 °C (-40 °F to 140 °F)
Unit
Danfoss Intelligent Purging System IPS 8 60Hz unit 084H5002
Accessories/Spare parts Accessory Spare part Code
Flange blind blank incl Bolts, nuts and Gaskets* x 084H5053
SV3 Float Valve x 027B2023
ICF 15-4 solenoid, DIN Butt weld 15mm ½ inch x 027L4543
ICF 15-4 solenoid, ANSI Socket weld 15mm ½ inch x 027L4538
ICF 15-4 solenoid, ANSI Butt weld 15mm ½ inch x 027L4602
Welding Flange incl Bolts, nuts and Gaskets x 084H5061
Purger solenoid kit (Armature, tube, Sealing, Orifice, Filter insert) x 084H5051
Solenoid coil, 24V DC for AKV x x 018F6757
PSU, 24V DC - optional for powering purge points x x 080Z0055
Restrictor, purge line x 084H5054
Compressor Cranck case heater x 084H5058
Condenser coil assy incl screws x 084H5059
Fan motor for condenser Incl fan grid and screws x 084H5060
Extraction Fan x 084H5056
Air grid with filter (1 piece) x 084H5057
Pre-programmed MCX 15 x 084H5052
Pressure transmitter evaporator, soldered (AKS 32R) x 060G3552
Compressor including Start relay box and Start and Run Capacitor x 123B2156
Compressor Hi-temp sensor x 084N2003
Expansion valve, R452A x 068U3881
Sight glass x 014-0191
Pressure transmitter - R717, Threaded, AKS2050 x 060G5750
Thermostat for crankcase heater control x 060L111166
Temperature sensor - R717, AKS 21M x 084N2003
Pressure switch for Fan x Contact Danfoss
Pressure safety switch x Contact Danfoss
* For closing system flange during system pressure testing
Code number
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Note:
All Spare part items are parts already built into
the IPS 8 All accessories are not.
© Danfoss | DCS (ms) | 2021.04
User Guide | Intelligent Purging System (IPS 8) Ammonia
Introduction
The Danfoss Intelligent Purging System (IPS 8)
is a stand-alone, self-contained purging unit
designed to remove non-condensable gases
(NC gases = air and other unwanted foreign
gases) from industrial ammonia refrigeration
systems.
The IPS control can handle up to 8 purge points
automatically.
The ingress of NC gases into a refrigeration
system is inevitable, regardless of the refrigerant,
pressures, or temperatures. NC gases in the
system will result in a decrease in system
efficiency, both in terms of an increase in power
consumption and reduced cooling capacity.
Due to having a different density than ammonia,
the ingressed air will accumulate in specific areas
of the system, where it can be removed using the
Danfoss IPS 8.
The accumulation areas are identified in the
Connection locations section, along with
recommended connection principles.
The purger unit is an electronically controlled,
self-contained R452A refrigerant system that runs
independent of the main ammonia system and
with only one flange connection to the ammonia
plant.
The flanged opening allows the ammonia gas/
NC gas mix access to the purger’s heat exchanger,
where it is split into ammonia condensate and NC
gases. The ammonia condensate is returned by
gravity to the main plant, while the NC gases are
purged to the atmosphere through e.g. a water
bath.
Through the flanged opening, the purger unit
has access to the parameters from the ammonia
plant required for full electronic control.
The unit runs automatically in 24-hour cycles,
checking for the presence of NC gases and, if
present, removes the NC gases.
To regain and retain the design capacity of the
main ammonia system and prevent future air
accumulation, it is highly recommended to install
the Danfoss IPS 8.
Features
• State-of-the-art electronically controlled unit
based on the Danfoss MCX controller platform
• Reduced power consumption of the ammonia
plant
• Automatic purging response to NC gases in the
refrigeration system
• Continuous and smart monitoring of
differential pressure between the system
refrigerant and the purger’s refrigerant
• Smart purging that minimizes refrigerant
(ammonia) release to the environment
• Self-contained unit operation, which functions
independently from the main plant
• An operation log for easy purging cycle data
monitoring
• Industry standard Modbus RTU
communication for remote monitoring and
system integration
• Reduced purging unit power consumption
compared to other units due to on-demand
operation only
• Self-diagnostics for both unit and system
operation to shut down in the event of
malfunctions
• Cost-effective installation with few mechanical
and electrical connections
• A fully brazed and leak-tested R452A cooling
system, minimizing leakage risks
• A plug-and-play stand-alone design, which
simplifies installation and commissioning while
reducing potential errors
• No need for advanced settings
• A compact and easy-to-handle design
• Patent pending on IPS 8
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User Guide | Intelligent Purging System (IPS 8) Ammonia
13
Working principle The Danfoss IPS 8 is factory-tested and ready to
use in ammonia plants with a condenser pressure
of more than 6,5 bar (94 psi). The purger is
charged with 900 gram (31.7 oz) of R452A.
Only 2 mechanical connections are needed for
the purger (see fig. 1). The flow of ammonia/NC
gases from the main plant is done through the
flange for ammonia (see 13 in Fig. 1 below), while
the NC gas purge is done through the blow-off
pipe after the purge restrictor (18).
Through the flange for ammonia (13), a mixture
of ammonia gas and NC gases enters the heat
exchanger (12) part of the purger.
The ammonia gas/NC gas mix is cooled down
below the condensing temperature of the
ammonia by the R452A circuit. At this point,
ammonia gas condenses and returns by gravity
to the ammonia plant whereas the NC gases
accumulate in the heat exchanger (12) for
subsequent purging.
7
By condensing the ammonia gas, a new
ammonia/NC gases mix is naturally pulled
through. This new mix is separated through a
continuous process.
As the NC gas concentration in the heat
exchanger (12) increases, the R452A heat
exchanger pressure and temperature will
simultaneously decrease.
The controller continuously monitors the R452A
heat exchanger pressure as well as ammonia
pressure and temperature. When the R452A
pressure reaches a predefined pressure difference
when compared with the ammonia pressure
(temperature) it prepares to purge the NC gases
through the solenoid valve (16). The blow-off
is activated by the solenoid (16) and through
appropriate piping/hosing, should be led into
a water bath. This process is recommended
to retain small amounts of ammonia (see
Installation section).
19 20
6
4
3
1a
1
Fig. 1 - Purger R452A lay-out
1 Compressor R452A 11 Expansion valve, R452A
1a Compressor Cranck case heater 12 Heat exchanger Ammonia/R452A
2 Thermostat for crankcase heater control 13 Welding Flange
3 Discharge temp sensor R452A 14 Pressure transmitter R452A
3a Suction temperature sensor R452A 15 Pressure transmitter R717
4 Pressure safety switch 16 Solenoid valve AKVA and coil
5 Condenser 17 NC temperature sensor R717
6 Extraction fan 18 Restrictor, purge line
7 Pressure switch for Fan 19 MCX 15 (Pre-programmed)
8 Receiver 20 PSU, 24V
9 Filter 900 gram (31.7 oz) R452A
10 Sight glass
5
9
8
2
3a
14
10
11
12
15
16
17
18
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User Guide | Intelligent Purging System (IPS 8) Ammonia
Time
On
Off
Time
On
Off
Working cycle The Danfoss IPS 8 operates in 24-hour cycles, of
which 45 minutes are dedicated to an R452A pull
down. At power on, the pull down is initiated
immediately. If no NC gases are detected during
the 45 minute pull down, the system will close
the solenoid valve at purge point 1 and open the
solenoid valve at point 2. After a cycle time of 24
hours/N (Number of purge points), the
compressor will pull down again condensing the
ammonia. After 24 hours, all purge points have
been vented one time.
To identify NC gases, the controller utilizes upper
and lower thresholds for R452A evaporating
temperature. If, during pull down, the
temperature continues decreasing and the lower
threshold is passed, the controller considers
Power on
Purger Pull down
(PDT): 45 min
Cycle (CST) *
this to be a high concentration of NC gases
and opens the purge solenoid valve. The purge
valve will stay open until sufficient condensing
ammonia is present to lift the R452A evaporating
temperature above the upper threshold.
The compressor will continue running and if the
temperature again decreases below the lower
threshold, a new purge will be performed. This
process will be repeated until the R452A heat
exchanger temperature stays above the lower
threshold for >45 minutes following the previous
closure of the purge valve.
Purger Pull down
(PDT): 45 min
Cycle (CST) *
Purger Pull down
(PDT): 45 min
Compressor
On
Off
Purge valve
Fig. 2 - Power on & Cycle at no NC gases present: CST (compressor start time) and PDT (pull down time) are configurable
* Cycle (CST) = 24 hours/N (number of purge points)
Upper Threshold (VClseT)
Non condensables has been purged
- new cycle starts *
Evaporator Temp. (Tsat452)
Compressor
On
Off
Purge valve
Lower Threshold (VClseT)
Fig. 3 - Purging procedure - Low R452A evap. temperature detected during PDT: Thresholds are configurable
* If low evaporator temperature is detected (passing lower threshold), the purging procedure will be repeated immediately
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User Guide | Intelligent Purging System (IPS 8) Ammonia
Air traps
Fig. 4 Liquid level. Bottom connected receiver Fig. 5 Liquid level. Top connected receiver
For systems with low pressure liquid level control,
the correct condenser/ receiver installation is as
shown in Fig. 4 and Fig. 5.
The discharge gas from the compressor (1) is
led to the condenser (2) where it is condensed.
The receiver (3) holds the liquid until there is a
demand for liquid from the LP side, e.g., until the
expansion valve (4) opens. If the expansion valve
is closed, the liquid condensed in the condenser
will need to be stored in the receiver and the
level will increase. To ensure a free flow to the
receiver, the gas must be allowed to leave the
receiver; this process is accomplished through
the pressure equalizing line (a). The pressure
equalizing line makes the pressure in the receiver
the same as in the compressor discharge line.
The pressure in the condenser outlet is lower due
to the pressure loss in the condenser. Since the
condenser outlet pressure is lower than in the
receiver, it is therefore necessary to mount the
condenser higher than the receiver and allow for
a higher liquid level in the piping between the
condenser and the receiver (b).
The liquid column in the line (b) compensates for
the pressure difference between the condenser
outlet and the receiver.
Fig. 4 shows the liquid connection at the bottom
of the receiver.
If the liquid from the condenser is connected to
the top of the receiver (Fig. 5), a slightly different
arrangement must be made.
The liquid line (b) from the condenser to the
receiver will need to have a goose neck/liquid
trap to ensure that the liquid column is actually
established.
As air is heavier than ammonia gas, the air will
collect in two locations in this type of installation:
On top of the liquid in the receiver (x) and/or
on top of the liquid in the drop leg from the
condenser (y).
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