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
148R9653 |
ir.danfoss.com |
User Guide | Intelligent Purging System (IPS 8) Ammonia
Contents |
Legal notice................................................................................................................................................................................................................... |
3 |
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Technical data.............................................................................................................................................................................................................. |
4 |
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Ordering........................................................................................................................................................................................................................... |
4 |
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Introduction.................................................................................................................................................................................................................. |
5 |
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Features............................................................................................................................................................................................................................ |
5 |
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Working principle ..................................................................................................................................................................................................... |
6 |
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Working cycle............................................................................................................................................................................................................... |
7 |
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Air traps............................................................................................................................................................................................................................ |
8 |
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Connection locations.............................................................................................................................................................................................. |
9 |
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Connection points................................................................................................................................................................................................. |
11 |
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Installation................................................................................................................................................................................................................... |
12 |
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Electrical wiring ....................................................................................................................................................................................................... |
14 |
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Light Indicators......................................................................................................................................................................................................... |
16 |
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Quick Startup............................................................................................................................................................................................................. |
17 |
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General display......................................................................................................................................................................................................... |
17 |
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Configuring using the LCD............................................................................................................................................................................... |
18 |
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Modbus RTU.............................................................................................................................................................................................................. |
20 |
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Maintenance/Service/Disposal...................................................................................................................................................................... |
27 |
2 | BC344024774466en-000401 |
© Danfoss | DCS (ms) | 2021.04 |
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 |
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as product presentation and customer advisory service. It contains important information and |
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technical data regarding the product. |
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This product information should be supplemented with the information about the industrial safety |
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and health related regulations at the site of installation of the product. The regulations vary from |
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place to place as a result of the statutory regulations applicable at the site of installation and are |
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therefore not considered in this product information. |
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In addition to this product information and the accident prevention regulations applicable for the |
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respective country and area where the product is used, the technical regulations for safe and |
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professional work must also be observed. |
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This product information has been written in good faith. However, Danfoss cannot be held responsible |
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for any errors that this document may contain or for their consequences. |
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Danfoss reserves the right to make technical changes during the course of further development of the |
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equipment covered by this product information. |
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Illustrations and drawings in this product information are simplified representations. As a result of |
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the improvements and changes, it is possible that the illustrations do not exactly match the current |
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development status. The technical data and dimensions are subject to change. No claims will be |
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accepted on the basis of them. |
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Danfoss A/S
6430 Nordborg Denmark CVR nr.: 20 16 57 15
Telephone: +45 7488 2222
Fax: |
+45 7449 0949 |
EU DECLARATION OF CONFORMITY
Danfoss A/S
Refrigeration & Air Conditioning Controls
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 |
Issued by |
Date: YYYY.MM.DD |
Approved by |
Place of issue: |
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Place of issue: |
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Signature: |
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Signature: |
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Name: Su Cheong Ho |
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Name: Behzad Parastar |
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Title: Lead Design Engineer |
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Title: Product Manager |
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 |
Revision No: AA |
Page 1 of 1 |
This doc. is managed by 500B0577
© Danfoss | DCS (ms) | 2021.04 |
BC344024774466en-000401 | 3 |
User Guide | Intelligent Purging System (IPS 8) Ammonia
Technical data
Supply voltage |
230V AC, 1ph, 60Hz |
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Current |
5.7 A (max. 6.5 A) |
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Power consumption |
max. 1.3 kW |
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Short-circuit current rating |
Icc 10kA |
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Temperature range ambient |
-10 °C to +43 °C (14 °F to 109 °F) |
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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) |
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Max. operating pressure (PS) R452A |
28 bar (406 psi) |
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System refrigerant |
R717 |
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Min. operating pressure R717 |
6.5 bar (94 psi) |
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Max. operating pressure R717 |
40 bar (580 psi) |
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Operating temperature R717 |
-40 °C to +60 °C (-40 °F to 140 °F) |
Ordering |
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Unit |
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Code number |
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Danfoss Intelligent Purging System IPS 8 60Hz unit |
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084H5002 |
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Accessories/Spare parts |
Accessory |
Spare part |
Code |
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Flange blind blank incl Bolts, nuts and Gaskets* |
x |
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084H5053 |
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SV3 Float Valve |
x |
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027B2023 |
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ICF 15-4 solenoid, DIN Butt weld 15mm ½ inch |
x |
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027L4543 |
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ICF 15-4 solenoid, ANSI Socket weld 15mm ½ inch |
x |
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027L4538 |
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ICF 15-4 solenoid, ANSI Butt weld 15mm ½ inch |
x |
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027L4602 |
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Welding Flange incl Bolts, nuts and Gaskets |
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x |
084H5061 |
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Purger solenoid kit (Armature, tube, Sealing, Orifice, Filter insert) |
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x |
084H5051 |
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Solenoid coil, 24V DC for AKV |
x |
x |
018F6757 |
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PSU, 24V DC - optional for powering purge points |
x |
x |
080Z0055 |
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Restrictor, purge line |
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x |
084H5054 |
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Compressor Cranck case heater |
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x |
084H5058 |
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Condenser coil assy incl screws |
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x |
084H5059 |
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Fan motor for condenser Incl fan grid and screws |
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x |
084H5060 |
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Extraction Fan |
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x |
084H5056 |
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Air grid with filter (1 piece) |
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x |
084H5057 |
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Pre-programmed MCX 15 |
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x |
084H5052 |
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Pressure transmitter evaporator, soldered (AKS 32R) |
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x |
060G3552 |
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Compressor including Start relay box and Start and Run Capacitor |
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x |
123B2156 |
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Compressor Hi-temp sensor |
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x |
084N2003 |
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Expansion valve, R452A |
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x |
068U3881 |
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Sight glass |
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x |
014-0191 |
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Pressure transmitter - R717, Threaded, AKS2050 |
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x |
060G5750 |
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Thermostat for crankcase heater control |
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x |
060L111166 |
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Temperature sensor - R717, AKS 21M |
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x |
084N2003 |
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Pressure switch for Fan |
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x |
Contact Danfoss |
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Pressure safety switch |
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x |
Contact Danfoss |
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* For closing system flange during system pressure testing |
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Note:
All Spare part items are parts already built into the IPS 8 All accessories are not.
4 | BC344024774466en-000401 |
© Danfoss | DCS (ms) | 2021.04 |
User Guide | Intelligent Purging System (IPS 8) Ammonia
Introduction |
The Danfoss Intelligent Purging System (IPS 8) |
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is a stand-alone, self-contained purging unit |
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designed to remove non-condensable gases |
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(NC gases = air and other unwanted foreign |
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gases) from industrial ammonia refrigeration |
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systems. |
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The IPS control can handle up to 8 purge points |
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automatically. |
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The ingress of NC gases into a refrigeration |
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system is inevitable, regardless of the refrigerant, |
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pressures, or temperatures. NC gases in the |
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system will result in a decrease in system |
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efficiency, both in terms of an increase in power |
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consumption and reduced cooling capacity. |
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Due to having a different density than ammonia, |
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the ingressed air will accumulate in specific areas |
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of the system, where it can be removed using the |
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Danfoss IPS 8. |
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The accumulation areas are identified in the |
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Connection locations section, along with |
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recommended connection principles. |
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The purger unit is an electronically controlled, |
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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 |
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based on the Danfoss MCX controller platform |
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• Reduced power consumption of the ammonia |
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plant |
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• Automatic purging response to NC gases in the |
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refrigeration system |
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• Continuous and smart monitoring of |
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differential pressure between the system |
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refrigerant and the purger’s refrigerant |
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• Smart purging that minimizes refrigerant |
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(ammonia) release to the environment |
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• Self-contained unit operation, which functions |
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independently from the main plant |
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• An operation log for easy purging cycle data |
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monitoring |
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• Industry standard Modbus RTU |
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communication for remote monitoring and |
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system integration |
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• Reduced purging unit power consumption |
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compared to other units due to on-demand |
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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
© Danfoss | DCS (ms) | 2021.04 |
BC344024774466en-000401 | 5 |
User Guide | Intelligent Purging System (IPS 8) Ammonia
Working principle |
The Danfoss IPS 8 is factory-tested and ready to |
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use in ammonia plants with a condenser pressure |
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of more than 6,5 bar (94 psi). The purger is |
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charged with 900 gram (31.7 oz) of R452A. |
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Only 2 mechanical connections are needed for |
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the purger (see fig. 1). The flow of ammonia/NC |
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gases from the main plant is done through the |
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flange for ammonia (see 13 in Fig. 1 below), while |
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the NC gas purge is done through the blow-off |
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pipe after the purge restrictor (18). |
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Through the flange for ammonia (13), a mixture |
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of ammonia gas and NC gases enters the heat |
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exchanger (12) part of the purger. |
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The ammonia gas/NC gas mix is cooled down |
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below the condensing temperature of the |
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ammonia by the R452A circuit. At this point, |
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ammonia gas condenses and returns by gravity |
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to the ammonia plant whereas the NC gases |
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accumulate in the heat exchanger (12) for |
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subsequent purging. |
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).
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19 |
20 |
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7 |
6 |
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5 |
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4 |
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9 |
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8 |
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3 |
2 |
10 |
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1a |
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1 |
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11 |
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3a |
15 |
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16 |
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14 |
17 |
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18 |
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12 |
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13 |
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Fig. 1 - Purger R452A lay-out
1 |
Compressor R452A |
11 |
Expansion valve, R452A |
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1a |
Compressor Cranck case heater |
12 |
Heat exchanger Ammonia/R452A |
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2 |
Thermostat for crankcase heater control |
13 |
Welding Flange |
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3 |
Discharge temp sensor R452A |
14 |
Pressure transmitter R452A |
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3a |
Suction temperature sensor R452A |
15 |
Pressure transmitter R717 |
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4 |
Pressure safety switch |
16 |
Solenoid valve AKVA and coil |
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5 |
Condenser |
17 |
NC temperature sensor R717 |
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6 |
Extraction fan |
18 |
Restrictor, purge line |
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7 |
Pressure switch for Fan |
19 |
MCX 15 (Pre-programmed) |
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8 |
Receiver |
20 |
PSU, 24V |
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9 |
Filter |
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900 gram (31.7 oz) R452A |
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10 |
Sight glass |
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6 | BC344024774466en-000401 |
© Danfoss | DCS (ms) | 2021.04 |
User Guide | Intelligent Purging System (IPS 8) Ammonia
Working cycle |
The Danfoss IPS 8 operates in 24-hour cycles, of |
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which 45 minutes are dedicated to an R452A pull |
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down. At power on, the pull down is initiated |
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immediately. If no NC gases are detected during |
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the 45 minute pull down, the system will close |
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the solenoid valve at purge point 1 and open the |
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solenoid valve at point 2. After a cycle time of 24 |
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hours/N (Number of purge points), the |
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compressor will pull down again condensing the |
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ammonia. After 24 hours, all purge points have |
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been vented one time. |
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To identify NC gases, the controller utilizes upper |
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and lower thresholds for R452A evaporating |
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temperature. If, during pull down, the |
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temperature continues decreasing and the lower |
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threshold is passed, the controller considers |
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.
<![if ! IE]> <![endif]>Power on |
<![if ! IE]> <![endif]>Purger Pull down (PDT): 45 min |
<![if ! IE]> <![endif]>Purger Pull down |
<![if ! IE]> <![endif]>(PDT): 45 min |
<![if ! IE]> <![endif]>Purger Pull down |
<![if ! IE]> <![endif]>(PDT): 45 min |
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Cycle (CST) * |
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Cycle (CST) * |
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Time |
Compressor |
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On |
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O |
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Purge valve |
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On |
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O |
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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)
<![endif]>Evaporator Temp. (Tsat452)
Compressor
On
O
Purge valve
On
O
Upper Threshold (VClseT)
Non condensables has been purged - new cycle starts *
Lower Threshold (VClseT)
Time
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
© Danfoss | DCS (ms) | 2021.04 |
BC344024774466en-000401 | 7 |
User Guide | Intelligent Purging System (IPS 8) Ammonia
Air traps
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Fig. 4 Liquid level. Bottom connected receiver |
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Fig. 5 Liquid level. Top connected receiver |
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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).
8 | BC344024774466en-000401 |
© Danfoss | DCS (ms) | 2021.04 |